RAPID PROTOTYPING STUDY NO.1 INTRODUCTION TO RPT

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1 INTRODUCTION TO RPT STUDY NO.1 RAPID PROTOTYPING Rapid prototyping (RP) is a technology wherein the physical modeling of a design is done using a specialized machining technology. The systems used in rapid prototyping quickly produce models and prototype parts from three-dimensional (3D) computer aided design (CAD) model data, magnetic resonance imaging (MRI) scan data and such data created from 3D digitizing systems. Using an additive approach for building shapes, the systems in RP join different materials like liquids or powder to form some physical objects. Layer by layer, the RP machines fabricate these powdered ceramic, wood, plastic and metal powders using very small and thin horizontal cross sections of the generated computer model. Rapid prototyping is an emerging technology, the definition of which is derived from the key concept - making it rapid. Rapid prototyping is creating a profound impact on the way companies produce models, prototype parts, and tooling. A few companies are now using it to produce final manufactured parts. It is believed that rapid prototyping shall occupy a major share in manufacturing techniques in the years to come. Rapid manufacturing may be considered as an extension of Rapid-Prototyping technology. It involves automated production of pans by inanictions directly fed by the CAD data which is modeled earlier. Currently, only a few final products are prepared by these machines. This technology is not suitable for mass production but for small batches and one-off production articles, it is cheaper since no tooling is involved. Some of the final components that are produced are: customized dinner-wares, helmets for individual heads (customized), jewellery patterns, spark erosion electrodes and reverse engineering pans. STEPS IN RPT Creation of the CAD model of the (part) design, Conversion of the CAD model into Standard Tessellation Language (STL) format,

2 Slicing of the STL file into thin sections, Building part layer by layer, Post processing/finishing/joining. MAJOR RP TECHNOLOGIES: 1. Photo Masking or Solid Ground Curing technique. 2. LOM (Laminated Object Manufacturing) 3. SLA (Stereolithography) 4. FDM (Fused Deposition Modeling) 5. SLS (Selective Laser Sintering) 6. Thermo Jet Process 7. 3D Printing 8. Ballistic Particle Manufacturing (BPM) APPLICATIONS OF RPT: It is mainly used in modeling, Product Design and Development, Reverse Engineering applications, Short Production Runs and Rapid Tooling, In medical applications, RPT is used to make exact models resembling the actual pans of a person, through computer scanned data, which can be used to perform trial surgeries, RP techniques are used to make custom-fit masks that reduce scarring on burn victims, Selective laser sintering (SLS) has been used to produce superior socket knees, Very tiny, miniature parts can be made by electrochemical fabrication,

3 In jewelry designs, crafts and arts. FUTURE DEVELOPMENTS: As the Rapid Prototyping Technology gets further advanced, it can lead to substantial reduction in build-up time for manufacturing. Further improvement in laser optics and motor control can improve the accuracy. The development of new materials and polymers so that they are less prone to curing and temperature induced warpages. Much anticipated development is the introduction of non-polymeric materials including metals, ceramics, composites and powder metallurgy. Developments in ceramic composites can further increase the range of rapid prototyping. Currently, the size is also a restriction; capability for larger parts shall be expected in the near future. Currently, the demand is low and with the hunter technology advancement, awareness and training, this can be increased. Advancement in computing systems and viability to support net designs from a distant country to be fed directly on the RP machines for manufacturing is a new possibility. LIMITATIONS AND CHALLENGES AHEAD: Unfamiliarity with the application of RPT exists. Therefore, its complete adaptability a And how exactly this new and advanced technology will be of help and is not known. In view of high equipment cost, very few organizations can invest in these new machines. Currently, RPT is more limited to modeling, specimen making and designing. The RPT is at present limited to making of paper and plastic type products only.

4 Replacing steel by composites is still not easy and people fear its implications. RP companies usually limit the marketing efforts and industry awareness; hence most engineering and manufacturing professionals are not fully aware of the RP potentials. The SD300 Printer

5 Creates 3D models Concept modeler Plus: Creates parts for evaluation, demonstration and functional verification Desktop user friendly machine Office environment Intended for: engineers, industrial designers, 3D model users SD300 Capabilities Specifications Build material Engineered plastic Material color amber transparent Maximum model size 160 W, 210 L, 135 H Accuracy 0.2 mm (x,y); 0.3 mm (z) Input file formats STL Minimum wall thickness 1 mm Technology and operation concept Bottom to top layer by layer build-up Layer build-up cycle : 1. Preparing a new plastic sheet layer in the buffer 2. Glue application on the whole area 3. Ironing the new plastic sheet layer on the model block 4. Cutting the new plastic sheet layer according to the pattern 5. Trimming the new plastic sheet layer and roll back 6. Masking fluid application by the 3 AG pens 7.

6 SD300 3D Printer Components and parts 1. Top door 2. Side covers 3. Material compartment doors 4. Heating system 5. Operating panel 6. Feeder tray 7. Ironing unit 8. Work table 9. XY Plotter head 10. Cutting knife 11. Trim knife & Anti Glue pen station

7 12. Rear Panel : On/Off Switch Fuse Power cable inlet USB Connection Ventilation openings Anti Glue Cartridge Material Kit Consumables Plastic Material roll loading and replacement Glue container loading and replacement AG cassette replacement AG pens replacement

8 Getting started (practice) Initializing the printer Consumable loading: - Material roll - Glue cartridge - AG cassette and pens Hands on practice Control Panel and Menu options 1. Cancel model (NO / YES (finish layer)) 2. Lift model (yes/no) 3. Un-feed media (yes/no) 4. Initialize (yes/no) 5. Build test model (yes/no) 6. Firmware version

9 Sdview application software Model preparation Importing STL files Placing models on work table Scale, duplicate, rotate, chop, join, etc. Viewing the model geometry Placing additional cuts File management (SDM format) Build model

10 SD300 3D Printer The Workflo 1. Click BUILD and send the build file to the SD300 3D printer 2. Retrieve your model 3. Simply peel away the support material

11 SD300 3D Printer Support Removal Clean, dry parts, no chemicals or washes No special tools or lab equipment required Peeling cuts allow easy peeling of complicated geometries Z-Fold allows fast, continuous removal of excess material Geometry capabilities What can you build? Full size parts Up to build spec Thin walls and small features 1mm wall thickness required Cavities and Holes Under Cuts Posts, snaps and pins 1mm wall thickness required TROUBLESHOOTING Panel errors: Motor protection Xy home error Z home error Door open error Height check error Trimming error Take/return tool error

12 Hook error Iron home error No media Feeding error Ironing error Remove previous model No magnet error Replace cutting knife Troubleshooting: Printer power Solid VC material feeding Broken knives AG pens AG cassette Glue application Peeling SD300 3D Printer User maintenance Clean printer after each build Glue residues AG residues Plastic sheet particles Test build in case the printer was not in use for a week Clean bubbles if necessary

13 SD300 3D Printer Machine Safety Electrical safety measures Keep work area clear and free of clutter Inspect the power cord periodically for cracks, kinks or any other signs of wear Do not pull the Printer by the cords Keep the area dry Keep the area well lit Do not touch any moving parts Clean up any spills immediately. Good house keeping pays Do not wear loose clothing or dangling jewelry while working with the printer Keep all doors and panels closed during operation Working with the tweezers