RAPID PROTOTYPING & TOOLING

RPT

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Procedure suggested to cover RPT during July-Dec 2003

OH film material view all available videos visit to 3DPD,CMTI,GTRE,TATA-ELXSI (HAL FORGE& FOUNDRY,ADA) Lectures by Dr.Mukesh Agarwala, Sri.U.Chandrashekhar,Stratasys Division of scanned files on RM into 9 chapters-9 teams-for conversion to *.ppt files
Introduction

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PQCDM Drivers over Decades

Decade
1960

Importance/Emphasis/Theme
How to do more?

1970
1980

.& Cheaper?
& Better?

1990 2000

& Quicker? ..? Lean Thinking!?

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PROTOS -(GREEK)
FIRST ORIGINAL PRIMITIVE

PROTOTYPE- Original thing of which imitation/ improved form are made

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RM RT RP CAM CAD FOUNDATION

HIERARCHY OF TIME COMPRESSION TECHNOLOGIES

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TIME=Time to market = From C to C RP

SUBTRACTIVE
HIGH SPEED MACHINING

ADDITIVE

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Relations diagram on RPT

CAD
LASER BASIC PCP RESEARCH UV

CAM

Reduction of 3-D problem to one of Xx 2D by slicing

RAPID PROTOTYPING & TOOLING

PRESSURE OF OF COMPETITION COMPETITION

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RPT PROCESS
BASIC RESEARCH

INPUT CAD DATA

RPT

DIRECT PROTOTYPES SOFTTOOLINGS

RPT is a process of turning basic research & design work into a finished product faster with higher quality & at lower cost -Robert Lutz, President,Daimler Corp.,1992

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RM

RT
RP CAM

CAD
Time

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DESIGN

VERIFICATION

CAD
MASTER PATTERN RP RT

VERIFICATION CAM
product to market in the shortest possible time

RM

Real product produced in the right material from real manufacturing process

Advantages of various technologies (of time compression) is to minimize product lead time.

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Product Engineering Functions

A. To build the product for function B. To design the product for customer satisfaction C. To design the product for cost D. To design the product for ease of maintenance & assembly

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A. To design the product for function

(1) Build models for testing (2) Provide part prints
(a) Physical dimensions (b) Material (c)Special process required ,such as heat treatment,plating, painting,testing and so forth

(3) Provide tool design & construction aids

(a) Material layouts (b) Templates (c) Master models

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4. Provide specification manuals (a) Material specification-chemical analysis and physical properties (b) Specification for special process -chemical and physical properties for heat treatment,plating,painting and so forth. (c) Procedure for testing & inspection (d) Procedures and specifications for joining process such as welding, brazing, soldering,riveting and cementing. (e) Specification for threads,gears,splines,keys and so forth

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B. To design the product for customer satisfaction

1. Sales appeal (a) Appearance-color and styling (b) Improvements-changes and additions over the old model (c) Designs to meet the needs of the customer 2. Durability and life expectancy of product Parts are designed to satisfy customer by giving the durability expected in relation to the cost.

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C. To design the product for cost

1. Cost of product must be low enough to compete with similar parts 2. Cost must be high enough to provide a profit desired by the owner of the company 3. Cost must be in correct relationship with durability and life expectancy

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D. To design the product for ease of maintenance & Assembly

1. Accessibility for ease of parts repair & replacement 2. Design for ease in assembly & disassembly 3. Provide drawings for maintenance and method of assembly

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Tooling Specifications a)Design order b)Design function & description

PRODUCT ENGINEERING

Product specifications a) Part prints b)Engineering release c)Specification manuals Equipment & Machine Specifications

TOOL DESIGN
Tooling designs

PROCESS ENGINEERING
Production tooling

PURCHASING

TOOL SHOP
Mfg specifications a)operation routing b)operation sketches

METHODS & WORK MEASUREMENT

Manufacturing stds

PRODUCTION

a)Standard items b)Act breakdowns Production Machinery

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Design start
Idea formation Evaluation of feasibility &marketability Prototype development Prototype constructed Test prototype Sales Engg.&production evaluation Check patents Refine design

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Manufacturing sales

Make design layout

Make detail drawing Completed design engineered for production

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THE RP INDUSTRY
Definitions..
Fabrication

of a physical , three dimensional part of arbitatary shape directly from a numerical description (typically a CAD model ) by a quick,highly automated and totally flexible process.
Rapid Prototyping Report,October 1992

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Rapid prototyping: a term used to describe a three dimensional output technology that can make rapid reproductions of human error,perfectly
Adapted from a definition of Xerox by Merie L.Meacham

Technology, capable of directly generating physical objects from 3D graphical computer data.
Name coined by 3D systems for this new process

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Rapid Prototyping Classical Methods NC/CNC

SLA/MJM SLS LOM 3DP FDM SGC DSPC BPM

Additive, Layer - by - Layer processes

Solid Ground Curing Direct Shell Prod. Casting Ballistic Particle Mfg

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The RP Industry
1988

Applications for Rapid Prototyping Engineering concept and form /fit models Client presentations and consumer evaluations Bid proposals and regulation Certification Master of silicone rubber tooling Master for spray metal tooling (all processes)

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Master for die casting and sand casting (LOM) Master for epoxy tooling to be used for injection molding

Engineering functional models (limited Nylon) 1996 Tooling for injection molding (Rapid Tool ,DSPC, Quick Cast )

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What is Creativity?
Creativity is inventing,experimenting, growing, taking risks,breaking rules, making mistakes, having fun
Mary Lou Cook

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Advantages of RPT
Productivity gains Substantial cost savings Improved Product quality Ability to quickly transition from concept to market.

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Historic.
1984 1988 First functional prototype First commercial machine delivered to Chrysler by 3D Systems Inc. ,Valencia, CA USA. Pioneers RP & M Fundamentals of stereolithography
book by Paul F. Jacobs Ph.D Director R& D, 3D Systems

1992

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Contents
Insight into the RPT Technology,Theory, Analysis, Experiment, Test Data in general In particular covering Description of fundamental physical & software process, materials & equipment which form the foundation of this new technology.

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How to build a prototype? Quantitative evaluation of accuracy which can be realistically achieved Practical examples form Aerospace, automotive, medical device manufacturing Companies Alternatives approaches to 3D process

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Q : where do we see RPT in day to day life ?

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Stereo lithography or 3D printing SLA Stereolithographic Apparatus Das Ding SLA - 250 ( = ?) Chronometer John Harrison 1735 1775 20,000 Thomas Alva Edison 1879 25 years

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Gottlieb Daimler Karl Benz Stuttgart 1885 Mannheim 4wheeler 3wheeler 1.5 HP : 4 stroke Otto Cycle 0.75 HP : 2 stroke Otto Cycle Henry Ford 1908 23 years Xerox 1938 by Chester Carlson in US 1959 Productionised

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1947 John Von Neumann was the Prof. Of Maths at Princeton Uni. Mathematical Analyzer, Numerical Integrator & computer MANIAC,NJ
1960 First commercial mainframe Computer IBM

1980 First PC

33 years

Average concept to production ~ 25 years

We cant imagine life w/o clocks, bulbs, automobiles, copiers, computers

RPT M/C 1992 300 Nos in 17 Countries..

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Difficulties in understanding drawings by the builder especially w.r.t blind holes,interior passage ways,compound curved surfaces.. One real prototype is worth 1000 pictures!! Reduction of geometric errors though improved visualization No substitute for the chance of holding a part in your hand and look at it from all sides

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Rapid PDCA Iteration Correct errors in CAD & decide further action Geometrical verification to check whether design contains features desired & does not contain features not desired (e.g) 2.4 lit engine Visualize

Design in 3D CAD

Build on RP M/C (SLA .. )

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PDCA cycle of RP
Fabrication Of Proto

Physical

Visualization

FTM Optimization

Verifica A P tion C D

Generation Iteration

Analyze of Design of Sensitivity to a variations number

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RP
PRIMARY SECONDARY

3 D SYSTEM

RTV Spray metal molding Resin transfer molding (Epoxy Tool) Investment casting Abrading of EDM tools

Ciba-Geigy Process Combinations thereof..

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TURBINE BLADE
CAD SLA model Mold box-Ciba Geigy process Multiple wax patterns Investment shells Aluminium casting

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List of RP systems
3D System Stereolithography DTM Sintering (Fusing of particulates with a high power IR CO2 LASER) STRATASYS-Extruding heated plastic filament (ABS/Wax) material which solidifies on cooling HELISYS-cutting non-photo reactive materials like paper sheet by high power CO2 LASER CUBITAL-Flash exposure with a continuum UV (non-LASER) radiation PERCEPTION- Ballistic Particle Fusion

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PROTOTYPE
ACTUAL DIGITAL TOUCHABLE NONTOUCHABLE

PHYSICAL

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PHYSICAL
FUNCTIONAL Form Fit Function
Performance

NON-FUNCTIONAL

Endurance

Concept Aesthetic Mock up to (for Engrs (only for Mgmt convey overall only) approval) shape,size,color

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COMPARISON OF DIFFERENT NOMENCLATURES

#
1 2 3 4 5
NOMENCLATURE
AESTHETIC Simulation shape size FORM Accuracy in representing geometry FIT Fitness to checkout assembly with mating parts FUNCTION Performance only TOTAL FUNCTION Including Endurance

Production Material Simulation

CONCEPT MOCK-UP MODEL PART PROTOTYPE PART FUNCTIONAL PART

X X

X X

X X

X X X X

X X X X

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Rapid Prototyping
An enabling technology bringing * True simultaneous engineering * Time compression Any process by which a facsimile(exact copy) model or a master pattern is manufactured by layering technique directly from CAD data FFF- Free Form Fabrication
.

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PROTOTYPE
Form DFF3 Fit Function

MASTER PATTERN
DFM Thought for manufacture Split lines to enable correct parting of tool Draft angle to allow part to be efficiently ejected from tool Contraction allowance to compensate for material shrinkage Machining allowance

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Meanings of different levels of PROTOS

FULLY FUNCTIONAL (Including endurance) made FIT FORM of design matl. (Fitness to check out assy FUNCTION (however by a technology& Limited to with mating AESTHETIC parts)+ performance tooling that may be different from simulation (accuracy in actual prodn. shape/size representing Route color geometry)

MOCK UP MODEL PART

PROTO PART

FUNCTIONAL PART

CONCEPT MODEL CONTINUUM

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Further Advantages of RP
Flow visualization,to determine the flow pattern within ducting(Typically this data can be only established after making a physical component,obviously too late to rectify any design errors). By using RP model data,analysis on flow is done before toolings are made thereby improving quality & efficiency of final product.

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Stress Visualization

High TIME CUSTOMER COMPTECHNFOCUS RESSION OLOGY + + & QUALITY INNOVA

Area of focus & level of develpmt. COST Low Strategy 1950

TION

+
1980 1990 Years

1960

1970

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Advantages of RPT
1. TEXAS INSTRUMENTS
* Enhanced visualization capability * Engineers,Designers,Technicians & Managers discuss scaled plastic prototype parts & just not 2D drawings (FMEA)

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Cost less than 50% of conventional models Time less than 50% of conventional models

Cost Time M/C g from solid Wax tool pattern SL

Typing v/s Computer

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2 CHRYSLER CORPORATION * Helps us to build correctly toleranced prototype without delay due to print errors,interpretations,machining inadequate sections * Built in 2 year 24 hr/day operation greater than 1500 parts 3 AMP * AMP able to send protoparts along with quotations.

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4. DEPUY INC.
* Enabler of real concurrent engineering (test of TQM..) (in ..4500 people are working..) * The goal of rapid prototyping is to bridge the communication gap by providing actual full sized physical models that each party can touch,analyze and use for further development.

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This capability has revolutionized DR meeting.The constructive dialogue among the members,as they pass the models to one another,suddenly allows everyone to express concerns & suggestions in a manner based upon a common level of visual understanding. * RPT has allowed a paradigm shift in concurrent process & product development.

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Each persons job is no longer just another step in the chain of events.Every individual can see the goal,the product & can relate to customer.They are a vital part of a team that is alive & functioning.The job is more challenging & rewarding as they are empowered to make decisions & see the direct results of their collective efforts. * If we are to continue as a society that manufactures things,then RPT is essential for our survival.

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RP = Layer Manufacturing
Liquid Solid Powder

C
Filament FDM

D
Sticky-backed paper LOM

E
Laser SLS

F
Glue 3DP MJM

Direct write Photomask/wax SL SGC

LAYER GENERATION Doubly ADDITVE & Purely Doubly ADDITIVE SUBTRACTIVE

ADDITIVE Purely & ADDITIVE SUBTRTACTIVE

Essentially ADDITIVE

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Overview of commercially available RP systems

Stereo lithography- SLA Multi Jet Modeling- MJM Fused Deposition Modeling- FDM Selective Laser Sintering- SLS Solid Ground Curing- SGC

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Laminated Object Manufacturing- LOM Direct Shell Production Casting- DSPC 3D Printing & Deposition Milling- 3DP Ballistic Particle Manufacturing- BPM

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PQCDM Drivers over Decades

Decade
1960

Importance/Emphasis/Theme
How to do more?

1970
1980

.& Cheaper?
& Better?

1990 2000

& Quicker? ..? Lean Thinking!?