ANSWER

1. Prototype is an approximation of a product or its component is some form for

a definite purpose in its implementation.
2. Implementation of prototype from entire product or system to its subassembles/component
Form of prototype from virtual to physical prototype
Degree of approximately of prototype from rough to accurate model
3. Experimentation and learning, Testing and proofing, Communication and
interaction, Synthesis and integration, Scheduling and marker.
Rapid prototyping allows designers to realize their concepts beyond virtual
visualization. This enables to understand the look and feel of the design, rather than
simply assuming through the CAD model. This helps designers to carry forward their
ideas and implement them in their design prior to finalization. It also provides a
proof of concept for the end client, seeking for a more realistic product design rather
than merely visualizing the design on screen.

4. The development of RP is closely tied in with the development of applications

of computers in the industry. The declining cost of computers, especially of
personal computers, has altered the way a factory works. The increase in the
use of computers has spurred the advancement in many computer-related
areas including computer-aided design (CAD), computer aided manufacturing
(CAM) and computer numerical control (CNC) machine tools. In particular, the
emergence of RP systems could not have been possible without the existence
of CAD. However, through careful examinations of the numerous RP systems
in existence today, it can be easily deduced that other than CAD, many other
technologies and advancements in other fields such as manufacturing
systems and materials have also been crucial in the development of RP
systems.
5. Prototyping processes have gone through three phases of development which
is
First Phase: Manual Prototyping
Prototyping had begun as early as humans started to develop tools to help
them live. However, prototyping as applied to products in what is considered
to be the first phase of prototype development began several centuries ago.
In this early phase, prototypes typically are not very sophisticated and
fabrication of prototypes takes on average about four weeks, depending on
the level of complexity and representativeness. The techniques used in
making these prototypes tend to be craft-based and are usually extremely
labor intensive.
Second Phase: Soft or Virtual Prototyping
As applications of CAD/CAE/CAM become more widespread, the early 1980s
saw the evolution of the second phase of prototyping Soft or Virtual
Prototyping. Virtual prototyping takes on a new meaning as more computer
tools become available and computer models can now be stressed, tested,

analyzed and modified as if they were physical prototypes. With such tools on
the computer, several iterations of designs can be easily carried out by
changing the parameters of the computer models.
Third Phase: RP
Mid-1980s, Benefit of a hard prototype made in a very short turnaround time
is its main strong point (relies on CAD modeling). Hard prototype can also be
used for limited testing and Prototype can assist in the manufacturing of the
products.
6. The invention series of RP methodologies is described as a watershed event
because of the tremendous time savings, especially for complicated and
difficult to produce models. Though parts are relatively three times as
complex as parts made in 1970s, the time required to make such a part now
averages only three weeks. Since 1988, more than 30 different RP techniques
have emerged and commercialized.
7. Rapid prototyping is a general term which describes a variety of systems that
can construct three dimensional models directly from electronic data. This
technology, first developed in the mid 1980s, is based on the solid modeling
portion of computer-aided design, or CAD. Solid modeling uses CAD data to
fully describe not only the parts overall shape, but also its interior volume
and outside surfaces.
Rapid prototyping systems use this data to build fabrications layer by layer in
very thin cross sections. Each layer is stacked upon a previous layer until the
model is complete. Rapid prototyping systems build intricate and complex
shapes much quicker and more simply than by conventional modeling
methods. Additionally, these systems can also produce models from data
generated from the 3-dimensional digitizing of existing parts, and medical
imaging devices.
Materials used to fabricate prototype models are broadly classified as either
liquid, powder, filament, or foil. Prototyping systems typically operate
untended, and upon completion, the fabricated models can require some
post-operations. these post processing operations includes surface finishing
and support removal. In total, however, the cost of prototype modeling is
greatly reduced from more conventional model shop fabrications.
8. The RP wheel shows four key aspects of RP. They are input, method, material
and applications.
Input - Input refers to the electronic information required to describe the
physical object with 3D data. There are two possible starting points which is a
computer model or a physical model. The computer model created by a CAD
system can be either a surface model or a solid model. On the other hand, 3D
data from the physical model is not at all straightforward. It requires data
acquisition through a method known as reverse engineering. In reverse

engineering, a wide range of equipment can be used, such as coordinate

measuring machine (CMM) or a laser digitizer, to capture data points of the
physical model and reconstruct it in a CAD system.
Method - While there are currently more than 30 vendors for RP systems, the
method employed by each vendor can be generally classified into the
following categories which is photocuring, cutting and gluing or joining,
melting and solidifying or fusing and joining or binding. Photocuring can be
further divided into categories of single laser beam, double laser beams and
masked lamp.
Material - The initial state of material can come in one of the following
forms: solid, liquid or powder state. In solid state, it can come in various
forms such as pellets, wire or laminates. The current range materials include
paper, nylon, wax, resins, metals and ceramics.
Applications - Most of the RP parts are finished or touched up before they
are used for their intended applications. Applications can be grouped into
design, engineering analysis and planning, and manufacturing and tooling. A
wide range of industries can benefit from RP and these include, but are not
limited to, aerospace, automotive, biomedical, consumer, electrical and
electronics products.
9. Benefits to Product Designers - The product designers can increase part
complexity with little significant effects on lead time and cost. More organic,
sculptured shapes for functional or aesthetic reasons can be accommodated.
They can optimize part design to meet customer requirements, with little
restrictions by manufacturing. In addition, they can reduce parts count by
combining features in single-piece parts that are previously made from
several because of poor tool accessibility or the need to minimize machining
and waste. With fewer parts, time spent on tolerance analysis, selecting
fasteners, detailing screw holes and assembly drawings is greatly reduced.
Benefits to the Tooling and Manufacturing Engineer - The main savings
are in costs. The manufacturing engineer can minimize design,
manufacturing and verification of tooling. He can realize profit earlier on new
products, since fixed costs are lower. He can also reduce parts count and
assembly, purchasing and inventory expenses.
Benefits to Marketing - To the market, it presents new capabilities and
opportunities. It can greatly reduce time-to-market, resulting in reduced risk
as there is no need to project customer needs and market dynamics several
years into the future, products which fit customer needs much more closely,
products offering the price/performance of the latest technology and new
products being test-marketed economically.
Benefits to the Consumer - The consumer can buy products which more
closely suit individual needs and wants. Firstly, there is a much greater

diversity of offerings to choose from. Secondly, one can buy (and even
contribute to the design of) affordable built-to-order products. Furthermore,
the consumer can buy products at lower prices, since the manufacturers
savings will ultimately be passed on.
10.Worldwide, the most commonly used term is RP. The term is apt as the key
benefit of RP is its rapid creation of a physical model. However, prototyping is
slowly growing to include other areas.
Rapid prototyping, tooling and manufacturing (RPTM) should be used to
include the utilization of the prototype as a master pattern for tooling and
manufacturing.
Some of the less commonly used terms include direct CAD manufacturing,
desktop manufacturing and instant manufacturing. The rationale
behind these terms is also based on speed and ease, though not exactly
direct or instant! CAD oriented manufacturing is another term and provides
an insight into the issue of orientation, often a key factor influencing the
output of a prototype made by RP methods.
11.The Rapid Prototyping systems that are liquid-based is
Solid Creation System (SCS)
- Cubitals Solid Ground Curing (SGC)
- 3D System Stereolithography Apparatus (SLA)
12.Through a process commonly known as curing, the liquid is converted to the
solid state.
13.The solid form can include the shape in the form of a wire, a roll, laminates
and pallets. The Rapid Prototyping systems that are solid-based is
- Cubic Technologies Laminated Object Manufacturing (LOM)
- Stratasys Fused Deposition Modelling (FDM)
- 3D System Multi-Jet Modelling System (MJM)
14.Method use in powder-based Rapid Prototyping is joining/binding. This
method differs for the above systems in that some employ a laser while
others use a binder/glue to achieve the joining effect.