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Rapid Prototyping Technologies

What is Rapid Prototyping


RP Technologies
Applications
How machine looks & Specs
Aero Engines
Pros & Corns
Conclusion

What is Rapid Prototyping


3D printingis a process of making three dimensional
solid objects from a digital file, typically by laying
down many successive thin layers of a material.
Also known as Additive Manufacturing (AM), Rapid
Prototyping (RP), Solid freeform fabrication, etc.,
The technology for printing physical 3D objects from
digital data was first developed by Charles Hull in
1984.
He named the technique stereolithography and
obtained a patent for the technique in 1986.
The same year, he founded 3D Systems and
developed the first commercial 3D Printing machine.

How Nature builds


Large 10 1 m

Small 10

-9

Technologies
Selective laser sintering (SLS)
/Melting (SLM)
Stereo lithography (SL)
Fused deposition modeling (FDM)
Laminated object manufacturing
(LOM )

Materials Options for 3D Printing


Metallic materials Plain Carbon Steel, Tool Steel,
Stainless steel, Aluminium, Copper, Titanium, Bronze, Nickel
Alumides
Polymers and Polymeric Composites - ABS, Nylon
(Polyamide), Polycarbonate, PP, Epoxies, Glass filled
polyamide, Windform, Polystyrene, Polyester,
Polyphenylesulfone
Others - Sand, Ceramics, Elastomers, Tungsten, Wax,
Starch, Plaster
Bio Compatible Materials - Polycaprolactone (PCL),
polypropylene-tricalcium phosphate, (PP-TCP), PCLhydroxyapatite (HA), polyetheretherketone-hydroxyapatite,
(PEEK-HA), tetracalcium phosphate (TTCP), beta tricalcium
phosphate (TCP), Polymethyl methacrylate (PMMA)

Prototyping technologies and


their base materials
3D Printing (3DP): Various materials, including
resins
3D Ceramic Printing: Various clay and ceramic
materials
Selective laser sintering (SLS): Thermoplastics,
metals, sand and glass
Fused Deposition Modeling (FDM): Thermoplastics
Stereolithography (SL): Photopolymer
Laminated object manufacturing: Laminate
sheets, often paper, and glue
Electron Beam Melting (EBM): Titanium alloys

Selective Laser Sintering


This is an additive manufacturing
technique that uses a high power laser
to fuse small particles of plastic,
metal, ceramic or glass powder into
the desired 3-D shape.
The laser selectively fuses the material
by scanning cross sections generated
from a 3-D digital description of the
part, for example a CAD file.

Fused Deposition Modeling


FDM works on an "additive" principle by
laying down material in layers. A plastic
filament or metal wire is unwound from a coil
and supplies material to an extrusion nozzle.
The nozzle is heated to melt the material and
can be moved horizontally and vertically. The
part, or model, is produced by extruding mall
beads of thermoplastic material to form
layers and the material hardens immediately
after extrusion from the nozzle

Stereolithography
Stereolithography is a process for
creating three-dimensional objects
using a computer-controlled laser to
build the required structure, layer by
layer. It does this by using a resin
known as liquid photopolymer that
hardens when in contact with the air.

Selective Laser Sintering


(SLS)/Melting(SLM)

Scanning
Mirror

Laser

Powder
cartridges Piston

Support

Roller
Part

1. Piston of the part built


chamber lower by one
layer;
2. Piston of powder
cartridges raise up;
3. Roller spread powder
evenly over the built
surface;
4. Laser beam scan over the
top of the part, melting
the powder and fuse it to
the previous layer;
5. Loop through the four
steps to build the next
layer.

Build
Chamber

Cont..

Direct Metal Laser Sintering (DMLS)/ DMLM


Direct metal laser sintering(DMLS) is
anadditive manufacturing technique that
uses alaseras the power source tosinter
powdered material (typicallymetal ),
aiming the laserautomatically at points in
space defined by a3D model, binding the
material together to create a solid
structure. It is similar toselective laser
sintering(SLS).

SLM & DMLS Videos


3D metal printing machine EOS M 29
0 - Rapid.Tech 2014.mp4
Additive Manufacturing - The Next In
dustrial Revolution.mp4
Direct Metal Laser Sintering.mp4
Direct Metal Laser Sintering (DMLS)
Technology.mp4

Aerospace
Do It Yourself
Automobile

Fashion&
Retail etc.,

Rapid
Prototypin
g

Medical

Reverse
Engineering

Food
Games &
Entertainment

Machine looks

Specification
Machin Build
e
volume
(mm x mm
x mm)

Build
speed

Layer
Laser
Thickness Power

Materil
as

SLM
500

500x280
x320

105 ccm /h

20m
-200m

1000 M
or
2x400

SS, Ti ,
Nickel
alloys
etc

EOSM
400

400 x 400
x400

2 -20 mm3/s 2m
-100m

1000W

SS, Ti ,
Nickel
alloys
etc

Concept 250 x250 x


Laser
280
M2

Sratasy

914 x610

2 -20 cm3/h

20m
-80m

SS, Ti ,
Nickel
alloys
etc

>178m

Thermo

Materials Standards for Additive


Manufacturing

Stainless Steel (17-4)

Steel 300

Parts made from 3D

Jet engine loading brackets are a crucial jet engine component, supporting
the weight of the engine during handling and they have to endure
significant vibrations during flight .

Milling

1.2 kg

3D Printing

0.6 kg

Low Pressure Turbine blade in -titanium aluminide. Courtesy

Overview

Japanese Company 3D Prints a Large


Working Jet Engine Replica

Electron Beam Melting (EBM) - Metal 3D Printing

Avio 3D-printed LPT blades for the


LEAP, GEnx, GE90 and GE9X jet
engines - See more at:
Additive manufacturing allows designers
to create parts like this jet engine
combustor that would be very difficult
to make on conventional machines

Medical

The Future of Medicine: 3D Printing and BionicOrgans!

Eyes on You

Defense
& Space

New technologies using Unmanned


Aircraft Vehicles (UAV) could create a
new,
cost-effective
and
reliable
monitoring service. Researchers at
University of Southampton, UK have
created a new 3D printed drone, called
2Seas, that could soon be used by
maritime security organizations. The
heart of 2Seas the central wing box,
fuel tank and engine mountings was
3D-printed, the wings and tail are made
from carbon fiber.

Drone It Yourself

Defense
& Space

Home-built drones are very popular


among hobbyists with backgrounds in
electronics and robotics. Jasper van
Loenen, an independent designer
working in the field of interaction design
and art, wanted to make the design
simpler so anyone could make their own
robots. Van Loenen created a custom
DIY (Drone It Yourself) v1.0 kit that
turns any object into an unmanned aerial
vehicle, simply by attaching four motors
and a control unit no technical knowhow needed.
http://vimeo.com/jasperl/diy

Liberator

Defense
& Space

Defense Distributed successfully test


fired the world's first 3D-printed
handgun named Liberator.
All 16 parts of the gun are made from a
tough, heat-resistant plastic used in
products such as musical instruments,
kitchen appliances and vehicle bumper
bars. Fifteen of those are made with a
3D printer while one is a non-functional
metal part which can be picked up by
metal detectors, making it legal under
U.S. law. The firing pin is also not made of
plastic, though it is easily crafted from a
metal nail.

3D-printed Lunar Base

Defense
& Space

Building a base on the moon could


theoretically be made much simpler by
using a 3D printer to construct it from
local materials. The concept was
recently endorsed by the European
Space Agency (ESA) which is now
collaborating with architects to gauge
the feasibility of 3D printing using lunar
soil.
3D printing offers a potential means of
facilitating lunar settlement with
reduced logistics from Earth, said Scott
Hovland of ESAs human spaceflight
team.

Advantages of additive Manufacturing

1. Efficient Use of recourses:


. Fewer processing steps, net shape, less assembly, less waste
material, less energy.

2. Freedom to Design and Innovate

If there is one thing that product engineers can count on, it is


that there will be modifications and redesigns

3. Optimized Design:

Less material Better function

4. Small lot production:


.

Even a lot size of 1.

5. Support of Green Manufacturing

Cont

6. Reverse engineering:

Scan and manufacture parts


for legacy systems

7. Complex Part manufacturing

Exotic structures, functionallygraded materials,


fabricate moving joints, embedded electronics

Aero Engines

This example of a high-pressure turbine blade was made from a


cobalt-chrome alloy on another type of 3D printer, the direct metal
laser melting (DMLM) machine.

Courtesy GE Aviation Each Leap engine will


contain 19 metal 3D-printed fuel nozzles. The
part is lighter and more durable than
traditional parts

Limitations of RP
Cost
Accuracy
Finish
Strength
Material Options

Conclusion

References

http://www.newscientist.com/article/dn23781-windows-aims-to-open-u
p-3d-printing-to-the-masses.html
.
http://www.newscientist.com/article/dn23785-printed-drones-to-hunt
-down-drugrunning-boats.html
.
http://www.psfk.com/2013/07/3d-printed-fashion-show.html.
http://www.stratasys.com/resources/case-studies
http://www.wikihouse.cc/
http://on3dprinting.com/wp-content/uploads/2012/08/20120806-Info
graphic-How-3D-Printing-Works-Preview.jpg
http://lunarscience.nasa.gov/articles/building-a-lunar-base-with-3d-prin
ting/

http://www.3ders.org/articles/20130706-3d-printable-drone-it-yourself
-kit-turns-any-object-into-an-uav.html
http://creativemachines.cornell.edu/ornithopter

Barnatt
, Christopher. "3D Printing."Explaining the Future. (2013): n.
page. Web. 16 Apr. 2013. <http://www.explainingthefuture.com/3dp
rinting.html>.
Cornell, Scott. "Disadvantages of 3-D Printers."azcentral
. n. page. Web. 16 Apr. 2013. <http://yourbusiness.azcentral.co
m/disadvantages-3d-printers-2212.html>.
Cubify 3-D Systems. Cubify. Web. 16 Apr 2013. <http://cubify.
com/cube/compare.asp&xgt;.
Evans, Hugh. "3-D Printing: The Game Changer."Connections
. n. page. Web. 16 Apr. 2013. <http://individual.troweprice.c
om/public/Retail/Planning-&-Research/Connections/3D-Printing/
The-Game-Changer>.
"Gartner Says Early Adopters of 3D Printing Technology Could
Gain an Innovation Advantage Over
Rivals."Gartner
. n. page. Web. 16 Apr. 2013. <http://www.gartner.com/newsro
om/id/2388415>.

Thank You

Applications
Aerospace:
-Engines, Interior, UAVs,

Automotive:
-Motor Racing, etc.,

Industry:
-Handling & Robotics, etc.,

Life style products:


-Jewellery, sports equipments, Foot wear,

Medical:
-Dental, Orthopedic Technology, Medical Devices,..
Reverse Engineering:
Educational & Research Labs:
Toys:

2 .STEREOLITHOGRAPHY
Stereo
lithography is an
additive
manufacturing
process using a
vat of liquid UVcurable
photopolymer
resin and a UV
laser to build
parts a layer at
a time.

GE Aviation uses additive manufacturing


methods such as direct metal laser melting
(DMLM) to build 3D-designed production engine
components that traditional manufacturing
methods are incapable of producing.

http://www.sparpointgroup.com/news/ge-aviation-speeds-up-production-of-3dprinted-jet-engine-parts-by-25#sthash.mkIJa2vT.dpuf

By 2020, GE Aviation will produce more than 100,000 additive manufactured


components for the LEAP and GE9X engines. GE will install 19 additive
manufactured fuel nozzles on every LEAP engine, which has amassed more than
4,500 orders.
The LEAP fuel nozzle is up to 25 percent lighter and five-times more durable than
traditionally manufactured fuel nozzles, leading to big fuel savings.

Today,Boeing(BA)uses the process


to make plastic air-conditioning ducts
for its 787Dreamliner jet, andNike(
NKE)has a football cleat made on 3D
printers.

The 3D printing process has facilitated the building of a


more efficient jet engine.
Last week, theMIT Technology Reviewreported that a
new incarnation of jet engines will mean aircraft use up
around 15 per cent less fuel thanks to their lighter
components, potentially saving some $1 million
(655,695, 776,217) annually per aeroplane, impacting
significantly on carbon emissions.
Additive manufacturing has the potential to reduce the
weight of a single aircraft engine by 1,000 lbs - See more
at: http://www.tctmagazine.com/software/ge-unveils-its10-global-open-innovation-jet-enginebracket-/#sthash.V9Wff2wx.dpuf

Ohio-headquartered GE Aviation is
using lasers to print fuel nozzles for
next-generation jet engines. These
nozzles are 25 per cent lighter and as
much as five times more hardwearing than the existing model
welded from 20 different parts.

EOS Materials

Rep Rap
Model:
RepRapPr
o Huxley
Price:
$599

Eventorbot
Model:
Delta Micro
Up Afinia HSeries
Price:
$1,500

Printrbot
Model:
Printrbot
GO
Price:
$1,500

Makerbot
Model:
Replicator
2x
Price:
$2,800

The Future
is 3D
Model:
Glacier
Steel
Price: 3000

3D
Systems
Model:
CubeX
Price:
$3000

Formlabs
Model:
Form 1
Price:
$3,300

Stratasys
Model: U
print SE
Plus
Price:
$15,000

Pressure to develop new and


highquality products
quickly and cost effectively.
Pressure for quick response
manufacturing and
rapid deployment of products
into production

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