BDD 4043 Rapid

Manufacturing
Chapter 1:
Rapid Product Development and
Manufacturing

Compiled by: Dr. Mustaffa Bin

Ibrahim
 Introducti
on
The dynamics of markets, technology, and
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competition have brought changes to

virtually every market sector and have made
new product development one of the most
powerful business activities.

New products may be defined as any product,

service, or idea not currently made or
marketed by a company, or which the
consumer may perceive as new.
 Market requirements for rapid product
development

What define the requirements of a product…

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Non specific or fast changing customer desires

Increasing significance of styling
Individualization of products
Environmental requirements
Decreasing lifetime of products
Decreasing prices
Regulations and standards
Interdisciplinary work
Spreading of resources
Legal circumstances
 Change of product lifetime based on 1992
for various branches of industry over time
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 What Defines the Value of a Product?

Who is the customer?

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
 What is the product from the consumer’s
perspective?
 What is the compelling reason to buy?
 What is the key benefit provided by the
product?
 What are the key points of differentiation?
 What makes that differentiation possible?
 What will sustain that differentiation/market
position?
 Critical Factors for Success and
Competitive Strategies
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What influence the success of a company

Shortening of the product development
time
Reduction of costs
Increase in flexibility (product and
production)
Improvement of quality
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The costs for identical changes

of a product at various phases
of product development
 The Cost of Rectifying Design Flaws
Increases Exponentially
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$10 $100 $1,000 $10,000 $100,000 $ ???

CAD Concept Prototype Mold Production Market

Construction Model Launch
 Models for Product Development
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Type of models
Proportional model
Ergonomic model
Styling model
Functional model
Prototype
Sample
 Steps of product development in
relation to various model definitions
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 Rapid Prototyping
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Traditional Methods

CAD Only

RP&M Rapid Prototyping

Enables the Making of
Physical Models From
Computer-Aided Design
(CAD) Data
 Model Making by Rapid Prototyping
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The conventional model making process rely on the joint

database in the form of two-dimensional (2D) drawings
and sketches.

When the model is being made there exists no defined

database to which other members of the team could refer.
Simultaneous engineering is therefore not feasible for the
duration of the model making.

In the rapid prototyping process the complete 3D

geometric information from the CAD is split into layer
information and the layers are built directly with the aid of
the computer.

Rapid prototyping processes build 3D models, only on the

basis of 3D CAD computer data.
 BDD 4043 Rapid Manufacturing

Steps of product
development

Conventional
Rapid
 Definition: Rapid Prototyping – Rapid
Tooling – Rapid Manufacturing
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Rapid Prototyping Technology And Its Applications

 Rapid Prototyping
A family of unique fabrication processes developed
to make engineering prototypes in minimum lead
time based on a CAD model of the item.
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The name given to a host of related technologies

that are used to fabricate physical objects directly
Rapid Tooling
from CAD data sources.
Rapid tooling describes those applications that are
aimed at making tools and molds for the production
of prototypes and pre-series products by using the
same processes as those used in rapid prototyping.
Rapid Manufacturing
Refers to the process of fabricating parts directly for
end-use from a rapid prototyping machine.
Rapid manufacturing (RM) is the use of additive
fabrication technology to directly produce useable
 Relation of rapid prototyping, rapid
tooling and rapid manufacturing
processes to the basic product
development phases
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 Rapid Prototyping History
As early as 1890, Blanther suggested a layered
method for making a mold for topographical relief
maps.
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In 1974, DiMatteo recognized that these same

stacking techniques could be used to produce
surfaces that are particularly difficult to fabricate by
standard machining operations.

The first commercial process was presented at the

AUTOFACT show in Detroit (US) in November 1987,
by a company called 3D Systems, Inc.
 Rapid Prototyping Development
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Models
Uses of RP
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Growth of RP
 Generic characteristics of RP
technology

Rapid prototyping processes belong to the generative (or additive)

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production processes. In contrast to abrasive (or subtractive)

processes such as lathing, milling, drilling, grinding, eroding, and
so forth in which the form is shaped by removing material, in
rapid prototyping the component is formed by joining volume
elements.

Rapid prototyping processes are 2½D processes, that is stacked

up 2D contours with constant thickness. The layer is shaped
(contoured) in an (x-y) plane two-dimensionally. The third
dimension results from single layers being stacked up on top of
each other, but not as a continuous z-coordinate.

The models are therefore three-dimensional parts, very exact on

the build plane (x-y direction) and the smaller the z-stepping is,
the more the model looks like the original.
principle of model generation by rapid prototyp
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 Why Rapid
Prototyping?

Because product designers would like to have a

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physical model of a new part or product design

rather than just a computer model or line drawing
Creating a prototype is an integral step in design
A virtual prototype (a computer model of the part
design on a CAD system) may not be sufficient
for the designer to visualize the part adequately
Using RP to make the prototype, the designer
can visually examine and physically feel the part
and assess its merits and shortcomings
 RP Applications: Design
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Designers are able to confirm their design by

building a real physical model in minimum time
using RP
Design benefits :
Reduced lead times to produce prototype
components
Improved ability to visualize part geometry
Early detection and reduction of design errors
Increased capability to compute mass
properties
 Examples of parts made by rapid prototyping processes
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 RP Applications: Engineering Analysis and
Planning

Existence of part allows certain engineering analysis and

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planning activities to be accomplished that would be more

difficult without the physical entity
Comparison of different shapes and styles to determine
aesthetic appeal
Wind tunnel testing of different streamline shapes
Stress analysis of a physical model
Fabrication of pre-production parts for process planning
and tool design
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mouse.
A two-button computer
 RP Applications: Tooling

Called rapid tool making (RTM) when RP is used to fabricate

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production tooling. Two approaches for tool-making:

• Indirect RTM method
A pattern is created by RP and the pattern is used to fabricate the tool
Examples:
• Patterns for sand casting and investment casting
• Electrodes for EDM
• Direct RTM method
RP is used to make the tool itself
• Example:
• 3DP to create a die of metal powders followed by sintering and
infiltration to complete the die
 Master for Silicone Rubber Mold
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 Rapid tooling for a rear-wiper-
motor cover
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 RP Applications:
Manufacturing
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Small batches of plastic parts that could not be

economically injection molded because of the
high mold cost
Parts with intricate internal geometries that could
not be made using conventional technologies
without assembly
One-of-a-kind parts such as bone replacements
that must be made to correct size for each user
 Starting Materials in
RP

Liquid monomers that are cured layer by

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1.
layer into solid polymers
2. Powders that are aggregated and bonded
layer by layer
3. Solid sheets that are laminated to create the
Insolid
addition
partto starting material, the various material
addition RP technologies use different methods of
building and adding layers to create the solid part
There is a correlation between starting material
and part building techniques
 Classification of Different RP
Techniques
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 Technologies that are used to fabricate
physical objects directly from cad data
sources - RP
3D CAD Modeling RP Interface (STL file) Slicing
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2D Layer Processing Work w/ Computer

RP part Fabrication Post Processing

• post curing
• polishing
...
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RP - STEREOLITHOGRAPHY
 Prototype
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Layered manufacturing of
pyramids

? Layered
manufacturing
KUIH LAPIS
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SLA
3DP

SLS
FDM

LOM
Conversion of a solid model of an object into lay
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Figure (only one layer is shown)

 Alternative Names for Rapid
Prototyping
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Layer manufacturing
Direct CAD manufacturing
Solid freeform fabrication
Rapid prototyping and manufacturing (RPM)
Indicates that RP technologies are being
used increasingly to make production parts
and production tooling, not just prototypes
 Advantages

RP systems can directly produce functional parts in limited

production quantities.
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Part produced have an accuracy and surface finish inferior to

those made by machining.
The ability to experiment with physical objects of any
complexity in relatively short period of time.
The product designers, can increase part complexity with
little effect on lead time and cost.
Designers can reduce parts count by combining features in
one piece parts (minimise machining and waste).
Designer can minimise material and optimise
strength/weight ratios without regard to the cost of
machining.
Finally, they can minimise time-consuming discussions and
evaluations of manufacturing possibilities.
 The reasons of Rapid Prototyping
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To increase effective communication.

To decrease development time.
To decrease costly mistakes.
To minimize sustaining engineering changes.
To extend product lifetime by adding necessary
features and eliminating redundant features early
in the design.
 Problems with Rapid
Prototyping
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Part accuracy:
Staircase appearance for a sloping part
surface due to layering
Shrinkage and distortion of RP parts
Limited variety of materials in RP
Mechanical performance of the fabricated
parts is limited by the materials that must
be used in the RP process