Manufacturing Processes for Engineering Materials, 4th ed.

Kalpakjian Schmid
Prentice Hall, 2003
Rapid Prototyping Processes
TABLE 10.6 Characteristics of Rapid Prototyping Processes.
SUPPLY
PHASE
PROCESS LAYER
CREATION
TECHNIQUE
PHASE CHANGE
TYPE
MATERIALS
Stereolithography Liquid layer curing Photopolymerization Photopolymers
(acrylates,
epoxies,
colorable resins,
filled resins)
Solid base curing Liquid layer curing
and milling
Photopolymerization Photopolymers
Liquid
Fused deposition
modeling (FDM)
Extrusion of
melted plastic
Solidification by
cooling
Thermoplastics
(ABS,
polycarbonate,
elastomer) and
wax
Ballistic particle
manufacturing
Droplet deposition Solidification by
cooling
Polymers, wax
Three-dimensional
printing
Binder droplet
deposition onto
powder layer
No phase change Ceramic,
polymer and
metal powder
with binder
Powder
Selective laser
sintering
Layer of powder Laser driven
sintering or melting
Polymers, metals
with binder,
metals, ceramics
and sand with
binder
Solid Laminated object
manufacturing
Deposition of
sheet material
No phase change Paper, polymers
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Stereolithography
FIGURE 10.41 Schematic illustration of the stereolithography process. Source: Courtesy of
A.S. Alpert, 3D Sytems.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Production of a
Stereolithography
File
FIGURE 10.40 The
computational steps in
producing a stereolithography
file. (a) Threedimensional
decription of the part. (b) The
part is divided into slices.
(Only 1 in 10 is shown.) (c)
Support material is planned. (d)
A set of tool directions is
determined for manufacturing
each slice. Shown is the
extruder path at section AA
from (c), for a fuseddeposition
modeling operation.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall Page 19-10
Solid-Base Curing
Figure 19.8 Schematic illustration of the solid-base-curing process. Source: After M. Burns,
Automated Fabrication, Prentice Hall, 1993.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Fused
Deposition
Modeling
FIGURE 10.42 Schematic
illustration of the fused-deposition
modeling process. Source: Courtesy
of Stratasys, Inc.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Support Structures in Rapid Prototyping
FIGURE 10.43 (a) A part with a protruding section that requires support material. (b)
Common support structures used in rapidprototyping machines. Source: Figure reprinted
with permission of the Society of Manufacturing Engineers, from Rapid Prototyping &
Manufacturing: Fundamentals of StereoLithography, copyright 1992.
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
Selective Laser Sintering
FIGURE 10.44 Schematic illustration of the selective-laser sintering process. Source: C.
Deckard and P.F. McClure.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall Page 19-11
Three-Dimensional Printing
Figure 19.9
Schematic
illustration of
the three-
dimensional-
printing
process.
Source: After
E. Sachs and
M. Cima.
Kalpakjian Schmid
Manufacturing Engineering and Technology
2001 Prentice-Hall Page 19-12
Laminated-Object Manufacturing
Figure 19.10 (a) Schematic illustration of the laminated-object-manufacturing process. Source:
Helysis, Inc. (b) Crankshaft-part example made by LOM. Source: After L. Wood.
(a) (b)
Manufacturing Processes for Engineering Materials, 4th ed.
Kalpakjian Schmid
Prentice Hall, 2003
RP in
Investment
casting
FIGURE 10.45 Manufacturing steps for investment casting that uses rapid-prototyped wax
parts as blanks. This approach uses a flask for the investment, but a shell method can also be
used. Source: 3D Systems, Inc.