Slovak University of Technology
Faculty of Material Science and Technology in Trnava
Machine Tools And
Devices For Special
Technologies
Rapid Prototyping
Rapid prototyping
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Based on the creating and using of virtual space
numerical model of the designed product.
Possibility of straight production of the designed
product model eventually of final product on the
base of 3D data transport from CAD system to
Rapid Prototyping system.
Prototype
First material visualisation of the
workpiece and it is for the next processing
of workpiece design necessary.
 Gets:

 Practical
information about function, quality of
product and about costs for his producing.
Prototyping
We can divided it into several groups:
 Mock – up – prototype gives to user the view how it approximately
look,
 Bread-board – prototype is using but yet has not created users
border line,
 Scale model – has users border line but supported only parts of all
conditions,
 Concept – car – where the prototype is generated to assignment of
market price,
 Simulation – where the prototype extracts screenplay and
conception of user,
 Characteristic model – formally specification of system,
 Blue-print – definition how to do really system implementation,
 Effectible Blue-Print - description how to do real implementation that
is output simulations
Advantage of Rapid Prototyping

In addition to possibility of fast model
production, patterns and prototype but
mainly production possibility of final lines
of modifications and constructed settings
of designed product.
Creating of 3D workpiece model
makes possible to:
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Fast creating of complex shape geometry and workpiece dimension
that are expressly described and teamed in screen of monitor
Automatic of cut creating and views to machined workpiece,
Create and verify other constructional variants of workpieces,
Simulated in the space of screen the kinematics it means
movements of particular parts of designed machine tool and to verify
possibility of collision becoming,
Realised study of built up the area and assembly kind of workpiece
or machine tool
Used generated data for Rapid Prototyping,
To set up the programs for machine tool controlling,
Simulated the process of workpiece machining in the screen,
include motions optimalization of tool and design of optimal cutting
conditions.
Design of the casts up, fixtures and tools for workpiece production.
Rapid Prototyping
Mutual aspect of these Rapid Prototyping
methods is that workpiece creating is
realised of layer to layer.
 Is possible to produce shape difficult
workpieces with :

 hollow
inside spaces,
 Horizontal and diagonal surface,
 Ribs
in the very short time.
Model design for Rapid
prototyping
Methods of Rapid Prototyping
I.
II.
III.
IV.
V.
VI.
VII.
Stereo lithography (Sl)
Solid Ground Curing (SGC)
Selective Laser Sintering (SLS)
Fused Deposition Modelling (FDM)
Laminated Object Manufacturing (LOM)
Direct Shell Production Casting (DSPC)
Model Market 3D Plotting and Ballistic Particle
Manufacturing (BMP) Multi Jet Modelling
I.
Stereo lithography (SL)
It is producing of the workpiece realised layer to
layer by hardening of the liquid photopolymer by
UV laser (photo polymerization).
On the base of created information about shapes
and dimensions are enumerated operated datas
that supported the laser beam by XY scanning
head.
Stereo lithography (SL)
1. Laser
2. Processing head
of laser
3. System for moving
of support desk
4. Support desk
5. Processing pool
6. CNC operated
system
7. Photopolymer
8. Support
9. Machined
workpiece
II.
Solid Ground Curing (SGC)
Producing proceeding of models based on
the photo polymerization where is rim
lighted through mask by UV lamp.
This method makes possible to create rangy
and shape difficult prototype workpieces.
Solid Ground Curing (SGC)
Advantages:
 In the SGC process is not needed making stronger,
 Complication of creating workpieces has not influence to
the time for their production
 Process of production are not dependenced,
 Damages layers can be after detecting immediately
milled.
 Can be produce synchronize more prototype
workpieces.
Solid Ground Curing (SGC)
Used polymers are relatively expensive,
 Production devices are very large, noisy
and expensive for maintenance,
 Necessity to remove the wax after
workpiece creating.
 Little selection of using input materials for
prototype components.

III. Selective Laser Sintering
(SLS)
Method based on the principle of the local
sintering, eventually melting of powder
materials by influence of laser beam.
Used the components of thermoplastic
materials, special low melting metal alloys
of nickel bronze and of polymers coated
powder.
Selective Laser Sintering (SLS)
Advantages:
 Cheap and no harmed healthy material,
 Large selection of used materials,
 Is not needed supported construction,
 Decreasing of destruction possibility of
inside stresses.
Selective Laser Sintering (SLS)
Disadvantages:
Roughness surface after final modification it
means „stairs“ effect,
Porosity of components,
Different intensity in various parts of generated
components,
Material transformations are needing cleaning of
the production device
Selective Laser Sintering (SLS)
– functional scheme
Device for Selective Laser
Sintering (SLS)
EOSINT P 360
IV. Fused Deposition Modelling
(FDM)
Component is processing by step to step
layering of material that is outgoing of
heated jet.
Principle of FDM method
V.
Laminated Object
Manufacturing
Method based on the shape cutting by
lasers of special foils and of their gradually
layering by sticking.
By this method is possible to produce
quantity of components eventually fast
because they has scanning only their
contours
Principle of Laminated Object
Manufacturing
VI. Direct Shell Production
Casting
Principle of this method is like the same as
in the method of Selective Laser Sintering.
Base material like powder is sticking by
liquid binding material.
With this method is possible to generated of
ceramic powder various components,
forms and casts for processes of straight
casting.
VII. Model Market 3D plotting
and Ballistic Particle
Manufacturing
Material coating is like that drops of material
(thermoplast) are darted to process
surface and after impact are hardened.
Model Market 3D plotting
Method that work with two pressure jets,
the first coating material and second
shaped it.
Method Ballistic Particle Manufacturing
Method process only with one pressure
head that has five degree of celsius.