(RP)

Ken Youssefi

MAE dept, SJSU

The design teams should use two methods for modeling and simulating a products performance.

Analytical (virtual, digital) models

Physical models (prototype)

Ken Youssefi

MAE dept, SJSU

Analytical (Digital) models

Computer generated models (3D solid model) are used to perform finite element analysis (stress, deflection, thermal, ), drop test, flow analysis, kinematics (motion) analysis and optimization.
Thermal analysis

Stress and deflection analysis

Ken Youssefi MAE dept, SJSU

Analytical (virtual) models

Drop test Flow analysis

Motion and Force analysis

Ken Youssefi

MAE dept, SJSU

Analytical (digital) models

Advantages Analytical models are more flexible than physical models. It is much easier to change parameters and to study different design scenarios. Less expensive than a physical model. Disadvantages The analytical model, due to theoretical limitation, may poorly estimate the actual product behavior. Analytical models cannot be expected to produce accurate results if the underlying physics is not well understood. A detailed model may require a long development time.

Unexpected phenomena and effects are most likely to be discovered during the physical prototype testing
Ken Youssefi MAE dept, SJSU

Physical models
There are two main considerations in the development of a physical model; Cost and Cycle Time It is not practical to build a prototype at every level of the product development stages. Due to competition, a new product has to enter the market at a fast pace. Improvement in solid modeling tools and design philosophy (concurrent engineering) has reduced considerably the number of physical prototypes needed to verify design parameters and configurations. Analytical (digital) model should be used to study the range of feasible parameters and then the physical model is used to verify and fine tune the design.
Ken Youssefi MAE dept, SJSU

Physical Prototype
A physical prototype is build for the following reasons: Verifying and Learning Does the product work? Does the product meet the design team specification and requirements? Does the product meet the customer needs? Integration Prototypes are used to ensure that different subsystems interface correctly. Communication A physical prototype makes it easier for the management, customers and vendors to visualize the design and MAE understand its function. dept, SJSU

Ken Youssefi

Prototyping Processes
Three major categories

Material Removal Casting/Molding Material Addition

Through out the years, many different production processes have been used to create prototypes (cast metal molds, epoxy molds, silicon rubber molds, injection molding, CNC machining ..). But in recent years, due to sophisticated computer software (3D parametric modelers), Material Addition Rapid Prototyping has emerged as the preferred process for many application.
Ken Youssefi MAE dept, SJSU

Rapid Prototyping (Direct Digital Manufacturing)

Rapid Prototyping Solid freeform fabrication involves constructing a three dimensional object one cross sectional layer at a time, depositing a material or by solidifying liquid or hardening powder. The object is first created using a 3D parametric modeler (Pro/E, Unigraphics, SolidWorks, ).
The popular commercial rapid prototyping processes can be categorized as: Stereolithography (laser fusion), FusedDeposition Modeling (FDM), Inkjet printing and Lamination.

Ken Youssefi

MAE dept, SJSU

RP Starting Materials
Liquid polymers that are cured layer by layer into solid polymers (plastics)

Solid polymer that is heated (melted) and deposited layer by layer to form the solid
Powder that is bonded layer by layer into a solid Solid sheets that are laminated to form the solid part

Ken Youssefi

MAE dept, SJSU

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Stereolithography (Liquid-Based)
Stereolithography (STL or SLA) was the first RP technology dating back 25 years.

The process uses photosensitive liquid polymer as the material. A laser beam is used to cure (harden) the liquid. The beam hits the liquid according to the path program generated by the CAD

The laser beam solidifies one layer at a time while the platform is lowered by the thickness of each layer.

Ken Youssefi

MAE dept, SJSU

11

The Stereolithography Process

You create a 3-D model of your object in a CAD program and save it as an .stl file A special software chops the CAD model up into thin layers typically 5 to 10 layers/millimeter. The 3-D printer's laser "paints" one of the layers, exposing the liquid plastic in the tank and hardening it.

The platform drops down into the tank a fraction of a millimeter and the laser paints the next layer.
This process repeats, layer by layer, until the model is complete. This is not a particularly quick process. Depending on the part size and number of layers, a typical run might take six to 12 hours. Runs over several days are possible for large objects.
Ken Youssefi MAE dept, SJSU

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Rapid Prototyping
3D solid model of the object The part is divided into slices

Only 10% of the slices are shown

Part is made one layer at a time

Ken Youssefi

MAE dept, SJSU

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Prototyping Processes
Stereolithography

The process is based on hardening a liquid photopolymer into a specific shape. Smallest tolerance that can be achieved is .0005
Ken Youssefi MAE dept, SJSU

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The platform at the end of a print run, shown here with several identical objects.

The platform in the tank of photopolymer at the beginning of a print run.

SLA
Video

The ultraviolet "oven" used to cure completed objects.

Ken Youssefi MAE dept, SJSU

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The wrench
Ken Youssefi MAE dept, SJSU

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Prototyping Processes
Fused-Deposition Modeling (FDM) starting material is solid polymer
A thermoplastic filament is extruded through a small orifice of a heated die. Layer thickness is between .01 to .02 inch, best achievable tolerance in vertical direction, tolerance of .001 inch is attainable in xy plane.

Ken Youssefi

MAE dept, SJSU

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FDM

The jet plane

Ken Youssefi MAE dept, SJSU

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mechanism

Ken Youssefi

MAE dept, SJSU

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uPrint machine

Ken Youssefi

MAE dept, SJSU

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Affordable 3D printer (ABS)

Ken Youssefi

MAE dept, SJSU

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Prototyping Processes - ZPrint

Binder
Powder storage Roller spreads a layer of powder material Standard inkjet printhead

Feed

Build

Piston lowers making room for new layer

Color printer
Ken Youssefi MAE dept, SJSU

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Inkjet Printing (powder 650 model)

Ken Youssefi

MAE dept, SJSU

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Working wrench

Ken Youssefi

MAE dept, SJSU

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ZPrint - examples
Consumer Products Size: 8 x 18 x 5 cm Printing Time: 2 hours

Footwear Size: 10 x 30 x 5 cm Printing Time: 3 hours

Automotive Size: 25 x 28 x 11 cm Printing Time: 8 hours

Medical Size: 25 x 20 x 10 cm Printing Time: 5.5 hours

Concept Modeling Size: 21 x 33 x 20 cm Printing Time: 12 hours

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Ken Youssefi

MAE dept, SJSU

3D dessert printer
http://money.cnn.com/video/technology/201 1/01/21/t_tt_3d_food_printer.cnnmoney/

3D model of Steven Colbert

http://ccinsider.comedycentral.com/2011/08/04 /3d-printer-creates-stephen-colbert-bust/

http://www.pcworld.com/article/229927/makerbot_3d_prints_ stephen_colberts_head_stephen_has_wings_and_tentacles who_knew.html

Ken Youssefi MAE dept, SJSU

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3D Metal Printing

Ken Youssefi

MAE dept, SJSU

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Bioprinting Organs The Future

Ken Youssefi

MAE dept, SJSU

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