RAPID MANUFACTURING TECHNOLOGIES
Introduction
Module I
- Creation of new system for the benefit of mankind
Dr. M.Sugavaneswaran
Asst. Prof. (Sr.)
SMEC
Rapid Prototyping/Manufacturing Introduction
“The fabrication of a physical, three dimensional part of arbitrary shape
directly from a numerical description - typically a Computer Aided Design model, by
a quick, highly automated and totally flexible manufacturing process”



•
Material
addition rapid
prototyping
Additive
•
Manufacturing
•
Welding
•
Material
removal
rapid
prototyping
•
Forging
•
Electro/Hydro
Drilling
•
Turning
Shaping
forming
Powder Metallurgy
COURSE PLAN
Module
Topics
Hours
I
Introduction to Rapid Manufacturing,: Additive Manufacturing evolution, 4
Additive manufacturing processes and their relationship with subtractive
manufacturing, Advantages of RM. Generalized rapid manufacturing process
chain, Rapid Tooling –Benefits, Applications.
II
Data Processing for Rapid Manufacturing: Conceptualization and CAD
model preparation, data formats – Conversion to STL file format, Fixing the
STL file, Part orientation, Support structure design, Model Slicing, Direct
and adaptive slicing.
4
III
Rapid Manufacturing Processes, Materials and its application: Sintering,
Powder Bed Fusion, extrusion, jetting, Photopolymerization, direct-write, sheet
lamination, directed-energy deposition and the latest state of the art. Multiple
Materials, Hybrids, Composite Materials, current and future directions.
4
IV
Post-Processing: Support material removal, surface texture improvement, 4
accuracy improvement, aesthetic improvement, preparation for use as a pattern,
property enhancements using non-thermal and thermal techniques.
2/8/2017
COURSE PLAN
Module
Topics
Hours
V
Design for Rapid Manufacturing (DFRM): Core DFAM Concepts and 4
Objectives: Complex Geometry, Customized Geometry, Integrated Assemblies and
Elimination of Conventional design for manufacture (DFM) Constraints. RM
Unique Capabilities, Exploring Design Freedoms and Design Tools for RM.
VI
Guidelines for process selection: Introduction, selection methods for a part, 4
challenges of selection, example system for preliminary selection, production
planning and control.
VII
Rapid Tooling: Direct tooling & Indirect Tooling methods, Reaction Injection
4
Molding, Wax Injection Molding, Vaccum Casting, RTV Silicone Rubber Molds,
Spin-Casting, Cast Resin Tooling.
VIII
Contemporary Discussion
2/8/2017
2
BOOKS AND
REFERNCES
Text Book
1. Ian Gibson, David W. Rosen, Brent Stucker (2015), Additive Manufacturing
Technologies: Rapid Prototyping to Direct Digital Manufacturing, 2nd Ed.,
Springer Science & Business Media.
Reference Books
2. Dongdong Gu (2014), Laser Additive Manufacturing of High-Performance Materials, ,
Springer Publications.
3. Ali K. Kamrani, Emad Abouel Nasr (2006), Rapid Prototyping: Theory and Practice,
Springer.
4. D.T. Pham, S.S. Dimov (2001), Rapid Manufacturing: The Technologies and
Applications of Rapid Prototyping and Rapid Tooling, Springer.
5. Andreas Gebhardt (2011),Understanding Additive Manufacturing, Hanser Publishers.
2/8/2017
Rapid Prototyping - Introduction
The roles that prototypes play
in the product development
process are several,
 Experimentation and learning
In present industrial scenario, RP/AM
plays major role from concept creation
 Testing and proofing
 Communication and
stage itself.
TESTG
VAUDATIOH
interaction
 Synthesis and integration
 Scheduling and markers
Rapid Prototyping - Introduction
Prototyping to Rapid Prototyping
o Prototyping of product enables the exploration, optimization, and validation of parts.
o Physical prototyping/crafting is traditionally a very time-consuming process.
o Recently with the assistance of computer, Rapid Prototyping (RP) has become a new
trend to produce a physical prototype for testing.
Prototype
For validation
Prototype
through
machining
Computer aided
prototype
Rapid Prototyping - Introduction
• COMPARISON OF TRADITIONAL & RP TECHNIQUE
RAPID PROTOTYPING
TRADITIONAL PROTOTYPING

Requires high skill

Easy to convert 3D-CAD
model to prototype

Made of plastic or
wood

Made of ABS plastics,
elastomers, metals etc.

Less flexibility

Larger lead time

Difficult to produce
Complex designs

High flexibility

Very short lead time

Very easy
Rapid Prototyping - Introduction
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TOPOGRAPHY
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PHOTOSCULPTURE
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HISTORY
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1968
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1987
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Photo sculpture
Digital and Virtual Prototyping
•
•
Digital prototyping is used to construct and build things.
Virtual prototyping is used to create animation.
What happens
when temperature
changes?
How will
failure
occur?
Will my
part fail?
What happens
if
I drop
it?
How do parts
interact?
How strong
does
it need to be?
Will 1t
overheat?
How light can
I
make it?
Will it handle
fluid
pressure?
e
Can I
produce
parts faster?
Will it have defects?
h t t p s ://www.youtube.com/watch?v=1Kai3k2rKW
M
2/8/2017
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A AUTODESK.
(Burdea &
Coiffet H
Rapid Prototyping To Rapid Manufacturing
PRODUCT DESIGN
•
TOOLING
(Patterns and Core Boxes)
MANUFACTURING
Direct use of CAD data in the production of a pattern and core box for the manufacturing of
the parts. This is also referred as Indirect RPT (Rapid Prototype Tooling) methods.
•
In direct RPT methods, the part fabricated by the RP machine itself is used as the tool.
•
In indirect RPT methods, the part fabricated by the RP machine is used as a pattern in a
secondary process. The resulting part from the secondary process is then used as the tool.
•
Because of direct use of RP part for manufacturing process, Rapid Prototyping is also known
as Rapid Manufacturing
Final product
from RP die
Indirect Tooling- Wax pattern from RP
Direct Tooling- ABS die from RP
RAPID TOOLING- INDIRECT
Wax patterns from RM process
2/8/2017
RAPID TOOLING- INDIRECT
Subtractive RM process
From additive or
subtractive
RM process
2/8/2017
Additive RM process
RAPID TOOLING- DIRECT
Plastic Mould from RM process
RAPID SOFT TOOLING
2/8/2017
Metal Mould from RM process
RAPID HARD TOOLING
Rapid Prototyping To Rapid Manufacturing
•
A natural extension of RP is Rapid Manufacturing (RM), the
automated production of saleable products directly from CAD data.
•
Custom-fitted helmet
•
NASA is experimenting with using RP machines to produce
spacesuit gloves fitted to each astronaut‟s hands.
•
From tailored golf club grips to custom dinnerware, the
possibilities are endless
Advantages of Rapid Manufacturing
 3D Parts reduce manufacturing costs and weight of the component.
 It has capability to produce a components in higher dimensional accuracy.
 Manufacturing lead time is very less.
 Model Customization is easiest one.
 “One-size fits all” to “all sizes to fit”.
 Zero-inventory manufacturing.
 Designer can see and feel the part and assess its merits and
shortcomings.
 Best for high functionality and less volume parts.
Rapid Manufacturing To Additive Manufacturing
•
Subtractive Vs Additive Prototyping Techniques
Subtractive – A block of finished materials is machined
down to make a product.
Requires tool and fixture selection.
Fast but more energy usage and large waste.
Additive- Raw materials is added/sintered/fused layer by
layer to make a product.
Doesn't required process planning such as tool and
fixture selection.
Moderately slow but least energy usage and minimum to
no waste.
Subtractive RM process – Suitable for 2.5
Dimension objects
Subtractive RM process – Suitable for axis symmetrical
object
https://www.youtube.com/watch?v=9E5MfBAV_tA
Additive RM process – Suitable for complicated parts
such as parts inside part as shown in image below
https://www.youtube.com/watch?v=eKk2vRysioE
Rapid Manufacturing To Additive Manufacturing
2009
Additive Manufacturing Technique
Additive Manufacturing
•
Additive Manufacturing is defined by American Society for Testing and Materials
(ASTM: F2792-12a) as „„process of joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to subtractive manufacturing methodologies,
such as traditional machining.‟‟
•
Additive manufacturing allows designers the option of building a part as a single unit,
from multiple materials, from the inside out.
•
This capability improves the precision of the product's fabrication and reduces
material waste
Additive Manufacturing - Standards
Source: Macias, Enrique & Hurley, John & Peruffo, Eleonora & Storrie, Donald & Packalén, Elisabeth. (2018). Game changing technologies: Exploring the
impact on production processes and work. Eurofound Working Paper. 10.2806/36769.
Additive Manufacturing
Comparison with other upcoming technologies
DESIGNATION
TITLE
 ISO / ASTM52915 -13  Standard Specification for Additive Manufacturing
File Format (AMF) Version1.1
 F2924 - 12a
 Standard Specification for Additive Manufacturing
Titanium-6 Aluminum-4 Vanadium with Powder
Bed Fusion
 Standard Specification for Additive Manufacturing
 F3001 – 13
Titanium-6 Aluminum-4 Vanadium ELI (Extra Low
Interstitial) with Powder Bed Fusion
 Standard Terminology for Additive Manufacturing
 F2792 - 12a
Technologies
 ISO / ASTM52921- 13  Standard Terminology for Additive ManufacturingCoordinate Systems and Test Methodologies
RAPID MANUFACTURING MARKET: WHO IS
USING ?
REVENUE SPLIT OF AM EQUIPMENT
CUSTOMERS
Medlcal
Archltccturcl
3%
Other
16%
I
Automoblle
21%
Academic
Aerospac
e
Military
7%
5%
10%
Wholers report 2013.
RAPID MANUFACTURING APPLICATIONS
Other
4%
Casting patterns
Tooling patterns
9%
13%
Direct Tooling
5%
Visual Engr. Aids
18%
Proposals
6%
Visual tooling
aids
7%
Quoting
3%
Ergonomics
4%
Fit/Assmebly
16%
Functional
Models
16%
Courtesy: RP&T State of the Industry Report Wohlers Associates, Inc.
RAPID MANUFACTURING APPLICATIONS
Independent service providers worldwide generated an estimated $2.955 billion from the sale of
parts produced by additive manufacturing systems in 2017. This is up 36% from the $2.173 billion
reported for 2016.
Courtesy: RP&T State of the Industry Report Wohlers Associates, Inc.
RAPID MANUFACTURING APPLICATIONS
Courtesy: RP&T State of the Industry Report Wohlers Associates, Inc.
ADVANTAGES OF RAPID MANUFACTURING
•
The ability to produce complex and det•ailed
three dimensional forms.
Reduce lead times for unique parts. Unlike in
many machining operations, no jigs, moulds, or other
external support devices are needed to fabricate the
object.
•
The
additive
process
allows
for
deep
undercuts as well as features such as building
pieces
within
(even
enclosed)
other
RP Jigs and
Fixtures
RP Die
As most RP processes are completely enclosed, thus
pieces, producing very
little noise and waste,
a clean
properties that would be very difficult, if not production environment is produced that allows for the
impossible, to produce directly by any other means.
installation
environments.
Under Cuts
of
the
machines
into
nonindustrial
LIMITATIONS OF RAPID MANUFACTURING

Material dependent process

Design of machines is based on material used

Operation cycle time is a limiting factor

Accuracies obtainable are dependent on process & material
used currently ranges from 50 to 300 microns

Software capabilities

Temperature limitation ranges from100C to 120C

Size and related assembly issues

Mechanical properties of material
RAPID MANUFACTURING- APPLICATIONS
 Production of models and prototypes during a product’s development phase
 Parts for pilot series production in medical, automotive and aerospace industry
 Short series production where tooling costs for casting or injection moulding would
be too high
 Parts of high geometrical complexity which can not be produced by means of
conventional manufacturing (moulding, grinding, milling, casting, etc.)
 To mitigate current challenges such as worker safety in harsh environments,
decreases in skilled workforce availability, and waste of materials
 Effective for unique designs serving non-structural aesthetic purposes
 Potential applications of AM such as optimized topologies, customized parts, in
situ repair
Source: Delgado Camacho, D., Clayton, P., O’Brien, W. J., Seepersad, C., Juenger, M., Ferron, R., & Salamone, S. (2018). Applications of additive
manufacturing in the construction industry – A forward-looking review. Automation in Construction, 89, 110–119.doi:10.1016/j.autcon.2017.12.031
MEDICAL APPLICATIONS
MASS CUSTOMIZATION PARTS
Hip socket, Ala Ortho, Italy, made on
Arcam machine
Laser Sintered Hearing Aids,
EOS/Materialise
MEDICAL APPLICATIONS
MASS CUSTOMIZATION PARTS
Dental Crowns and Bridges, EOS
MEDICAL APPLICATIONS
Hip and Knee
Maxillofacial
Dental
As built and
final machined
RAPID MANUFACTURING PROCESS FLOW
2D CAD Drawing
t J\,funua] outlme/
Lattice Data
3DCAD
if!
JJ
�
A
Slicing
-
�
Layer-wise
assembly
30 CAD model
A
Point cloud data
3DCAD
STL(3D)
Layer information, SCL OT CI.I
------�---i
---------·----
Auxitiary geomeb)· (supports etc.)
�---------------�
Geometric data
30 CAD model
Sliong distance
L
Final
Threshold
_
Photoresist
CAD File
Absorption
Process parameters.
Machine parameters
Specification of
machine Iaver
infon:nati;n
Hatching distance
3D printing.,.
3D reconstruction
2_ID reccnstrucfion
Reverse Engineering
Complete part
..
Data acquired from
I\·IRI OT CT scan
Numerlcal Slicing
Layer Processing
Layer by layer
Final Component
Manufacture
Courtesy:Gebhardt, 2003
mlcropart
RAPID MANUFACTURING PROCESS FLOW CHAINSUMMARY
PROCESS FLOW
CAD Modeling
STL File
Part orientation
Support structure generation
Slicing
Tool path generation
Part Fabrication
Post Processing
RAPID MANUFACTURING PROCESS FLOW CHAINSUMMARY
PROCESS FLOW
CAD Modeling
STL File
Part orientation
Support structure generation
Slicing
Tool path generation
Part Fabrication
Post Processing
RAPID MANUFACTURING TECHNIQUES
CLASSIFICATION
Rapid (Additive) Manufacturing
Binder jetting
Directed energy deposition
Material extrusion Material
jetting
Powder bed fusion
Sheet lamination
Vat photopolymerization
Source: ASTM International Committee F42 on Additive Manufacturing Technologies