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1.1 Rapid prototyping Chapter 1 Introduction Rapid prototyping is a form of manufacturing where the materials are added layer by layer to definite points in space to build up a solid part. This type of technology is often referred to as also layered manufacturing, rapid manufacturing or additive fabrication. During the beginning stages of use of this technology it was mainly used to build smaller models or prototypes of new products or products being developed but due to their much wider range of applications, they are now being used in different fields. They range in various sizes depending upon their need and quality desired. They are also suited when high quality parts have to be made for relatively small numbers. Rapid prototyping involves a process in which a 3D model of the desired part is built layer by layer through the process of additive fabrication. Modeling software such as Solid works or other animation software can be used for the purpose of modeling which is then converted into thin slices. The sliced file has all the information of the specific points which are the shape and geometry of that particular slice or layer. These slices when stacked one on top of the other will encompass the whole part. Charles W Hull was the first to create a unique method of Rapid prototyping [1] which later became available to others as this form of technology grew and more people wanted to build prototypes and models for testing and evaluation purposes. Rapid prototyping finds itself of use in a wide range of industries such as Aerospace, Military, Consumer products but so far is majorly adopted by the motor vehicle industry. The typical design process in Rapid prototyping is as follows – Concept, Preliminary Design, Preliminary fabrication, Test Production and then Final production. 14
Fig 1.1 The Rapid prototyping Cycle The Rapid prototyping cycle shown above in Fig 1.1 is a basic outline of the whole process. It starts with the initial CAD design of the required part, which is then converted into a STL (Stereo Lithography) file. This STL file is a raw file and depending upon the machine to be used upon, it can be either fed in directly or given for pre-processing. This type of processing may include checking the file, slicing, deleting or addition of parameters for machine control. The main feature of Rapid prototyping process is its ability to give life to any 3D model, regardless of its shape and specific features which would otherwise be difficult to manufacture through the normal machining process. It can be used to print different parts with complex shapes and features. In order to manufacture a model with the traditional methods of machining, it can take a long time ranging from days to months depending upon the shape, size or any other intricate feature of the model desired. With Rapid prototyping, this time required is substantially reduced compared to the earlier method. 15
Page 1 and 2: An Investigation into curved layer
Page 3 and 4: Contents Abstract..................
Page 5 and 6: 3.5.2 Fabepoxy.....................
Page 7 and 8: methodology to print simple curved
Page 9 and 10: List of Figures 1.1 The Rapid proto
Page 11 and 12: 4.3 Parts being tested with Hounsfi
Page 13: List of Abbreviations 3D: Three dim
Page 17 and 18: 1.1.1 Stereolithography Stereolitho
Page 19 and 20: The object to be made is first mode
Page 21 and 22: 1.1.5 Laser Engineered Net Shaping
Page 23 and 24: 1.2 Fused Deposition Modeling A det
Page 25 and 26: Fig 1.8 Deposition Head Different t
Page 27 and 28: 900mc is capable of producing parts
Page 29 and 30: noted that the parts built in this
Page 31 and 32: structure. Honeycomb scaffold archi
Page 33 and 34: optimal direction to build a part t
Page 35 and 36: processing treatment was analyzed w
Page 37 and 38: The actual influence of the curved
Page 39 and 40: Separating the Main part with its s
Page 41 and 42: limited to simple models. It could
Page 43 and 44: Fig 2.2 Faces, Edges and Vertices o
Page 45 and 46: 2.1.5 Constructive Solid Geometry C
Page 47 and 48: A STL file is a triangular represen
Page 49 and 50: Fig 2.8 A sample Binary STL File Sl
Page 51 and 52: Different processes may either vary
Page 53 and 54: At the very outset of generating th
Page 55 and 56: and correction of each point to sat
Page 57 and 58: apid prototyping machine are remove
Page 59 and 60: Fig 2.13 Main Part Fig 2.14 Support
Page 61 and 62: As this text file is to be used wit
Page 63 and 64: mounted to the axes carriage. Timin
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Fig 3.1 The deposition head At the
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3.2.3 Assembling Electronics and ca
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microcontroller is now disconnected
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The relationship between test point
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on the mechanical properties and po
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3.5.1 Silicone with other materials
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Fab@home machine. Since our require
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are printed using the two suitable
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The support structure‟s dimension
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machine Fig 3.13 Flat and curved la
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4.1 Experimental conditions Chapter
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have many factors from contention a
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4.3 Taguchi methods There are two t
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Such steps usually identify the nee
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Nominal is best Larger is better S
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Control of material flow - The lead
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Fig 4.3 Parts being tested with Hou
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values in all cases are almost doub
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level. The other parameters were in
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The finite element method has had a
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performance of finished FDM parts [
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ehaviour with failure occurring at
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Fig. 2 (a) is the thin curved part
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Table 5.1 Property data: Fabepoxy M
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optimum number. The final finite el
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Fig. 5.11 Load and boundary conditi
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overall deflection pattern of two s
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Fig. 5.13 Variation of compressive
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Fig. 5.15 shows the overall deforma
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The effectiveness of the deposition
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[11] M. Greul, T. Pintat, M. Greuli
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[32] Philip J. Ross, 1988, “Taguc
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