ATRIA INSTITUTE OF TECHNOLOGY

RAPID PROTOTYPING

submitted by
SHAHBAZ HUSSAIN DARZI(1AT13ME419)
GUIDE : Mr. KRISHNAPPA
(DEPT. MECHANICAL ENGG)

CONTENTS
INTRODUCTION
BASIC

PRINCIPLES OF RAPID PROTOTYPING

PROCESSES
EXAMPLE OF PROTOTYPING
RAPID PROTOTYPING TECHNOLOGIES
MAJOR APPLICATIONS OF RAPID PROTOTYPING
ADVANTAGES AND LIMITATIONS
CONCLUSION
REFERENCES

ABSTRACT

The term rapid prototyping (RP) refers to a class of

technologies that are used to produce physical objects
layer-by-layer directly from computer-aided design (CAD)
data.

In rapid prototyping, the term rapid is relative; it aims at

the automated step from CAD data to machine, rather than
at the speed of the techniques.

The costs are reduced because rapid prototyping processes

are fully automated and therefore need the skill of
individual craftsmen for no more than finishing the part.

INTRODUCTION

Rapid Prototyping (RP) can be defined as a group of

techniques used to quickly fabricate a scale model of a
part or assembly using three-dimensional computer aided
design (CAD) data.

Rapid Prototyping has also been referred to as solid freeform manufacturing, computer automated manufacturing,
and layered manufacturing .

BASIC PRINCIPLES OF RAPID

PROTOTYPING PROCESSES
Rapid

Prototyping process belong to the generative

production processes unlike subtractive or forming
processes such as lathing, milling,etc. in which form is
shaped by material removal or plastic deformation.
There are several rapid prototyping techniques exist, all
employ the same basic five-step process. The steps are:

Create a CAD model of the design

Convert the CAD model to STL format
Slice the STL file into thin cross-sectional layers
Construct the model one layer atop another
Clean and Finish the model

General Methods employed for Rapid Prototyping

Generalized illustration of data flow in RP

EXAMPLE OF PROTOTYPING
Rapid prototyping is a technology that takes a threedimensional computer model and builds a three dimensional
part by building layers upon layer of material. Its speed and
low cost allow design teams to confirm their new designs
early and frequently in the process.

Step 1
Step 5

Step2

Step 3

Step 4

RAPID PROTOTYPING
TECHNOLOGIES
The professional literature in RP contains different ways of
classifying Rapid Prototyping processes. Few important RP
processes are namely: Steriolithography
Fused

Deposition modeling (FDM)

Selective

Laser Sintering (SLS)

Laminated
3D

(SLA)

Object Manufacturing (LOM)

Printing

Direct

Metal Laser Sintering (DMLS)

Steriolithography

Stereolithography is the most widely used RP-technology.

In this process photosensitive liquid resin which forms a
solid polymer when exposed to ultraviolet light is used as
a fundamental concept.

Fused Deposition modelling (FDM)

FDM was developed by Stratasys.

In this process, a plastic or wax material is extruded
through a nozzle that traces the parts cross sectional
geometry layer by layer.

Selective Laser Sintering (SLS)

SLS was patented in 1989.

The basic concept of SLS is similar to that of SLA.
It uses a moving laser beam to trace and selectively
sinter powdered polymer and/or metal composite
materials.

Laminated Object Manufacturing

(LOM)

It can be seen from the figure that the slices are cut in
required contour from roll of material by using a 25-50
watt CO2 laser beam.
A new slice is bonded to previously deposited slice by
using a hot roller, which activates a heat sensitive
adhesive.

3D Printers

Three Dimensional Printing (3DP) technology was

developed at the MIT.
The process is similar to the SLS process, but instead of
using a laser to sinter the material, an ink-jet printing
head deposits a liquid adhesive that binds the material.

Direct Metal Laser Sintering

DMLS technology was developed jointly by Rapid

Prototyping Innovations (RPI) and EOS in 1994.
It was the first commercial RP-method to produce metal
parts in a single process.
Metal powder (20 m diameter) without binder is
completely melted by scanning of a high power laser
beam.

MAJOR APPLICATIONS OF RAPID PROTOTYPING

Automobiles:
Different

Alternative Inlet Manifolds were required to be

built. Three major parts were made by laser sintering.

Toy Industries:
The performance of Formula One racing car can be tested by
preparing a rapid prototype model with the help of wax
modelling.

Medicine:
Models of skull and other body structure can be used for
training of medical surgical operation in various hospitals
and medical institutions.

Architecture:
To prepare a model of house or a terrain with the help of
3D modelling.

ADVANTAGES AND
LIMITATIONS
ADVANTAGES:
Rapid

Prototyping can provide with concept proof that would be

required for attracting funds.

The

Prototype gives the user a fair idea about the final look of the

product.
Rapid
It

prototyping can enhance the early visibility.

is easier to find the design flaws in the early developmental

stages.

LIMITATIONS:
It

could so happen that some important developmental steps

could be omitted to get a quick and cheap working model.

Another

disadvantage of rapid prototyping is one in which

many problems are overlooked resulting in endless

rectifications and revisions
One

more disadvantage of rapid prototyping is that it may

not be suitable for large sized applications.

The

user may have high expectations about the prototypes

performance and the designer is unable to deliver it.

CONCLUSION
RP

is a technology that can be used for many different

applications,

both

manufacturing

and

non-

manufacturing based.
It

can enhance and optimize the product development

process.
It

can be concluded that RP has made a good

introduction and has a bright future in making PD more

effective and efficient.

REFERENCES
Rapid

Prototyping: Theory and Practice by Kamrani, Ali K.

Solid

Modeling and Applications: Rapid Prototyping, CAD

and CAE Theory by Dugan Um.

Additive

Manufacturing Technologies: 3D Printing, Rapid

Prototyping, and Direct Digital Manufacturing by by Ian

Gibson and David Rosen.
Rapid

Prototyping: Principles and Applications by Chee

Kai Chua, Kah Fai Leong, Chu Sing Lim.

THANK YOU