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RY57 PRODUCT DEVELOPMENT PDT 234/3 RAPID PROTOTYPING 1

TYPE & TECHNIQUE OF RAPID PROTOTYPING. RY57 PRODUCT DEVELOPMENT PDT 234/3 RAPID PROTOTYPING 1. Prepared by Mohd Haidiezul Jamal b. Ab Hadi. TYPES OF RP. TYPE & TECHNIQUE OF RAPID PROTOTYPING. LIQUID BASED RP PROCESSES. TYPE & TECHNIQUE OF RAPID PROTOTYPING.

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RY57 PRODUCT DEVELOPMENT PDT 234/3 RAPID PROTOTYPING 1

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  1. TYPE & TECHNIQUE OF RAPID PROTOTYPING RY57 PRODUCT DEVELOPMENT PDT 234/3 RAPID PROTOTYPING 1 Prepared by MohdHaidiezul Jamal b. AbHadi

  2. TYPES OF RP

  3. TYPE & TECHNIQUE OF RAPID PROTOTYPING LIQUID BASED RP PROCESSES

  4. TYPE & TECHNIQUE OF RAPID PROTOTYPING

  5. TYPE & TECHNIQUE OF RAPID PROTOTYPING

  6. TYPE & TECHNIQUE OF RAPID PROTOTYPING SLA ( STEREOLITHOGRAPHY APPARATUS ) • First commercialized RP process • It works on principle of solidifying a photosensitive resin using UV laser light layer-by-layer to develop 3D object • Uses photocurable resin that can be classified as an : EPOXY VINYLETHER ACRYLATE

  7. TYPE & TECHNIQUE OF RAPID PROTOTYPING SLA PROCESS • Converts 3D computer image data into a series of very thin cross section • A vat of photosensitive resin contains a vertically moving platform • Part under construction is supported by the platform that moves downward by a layer thickness ( typically about 0.1mm ) for each layer • A laser beam then traces a single layer onto surface of a vat of liquid polymer. • The ultraviolet light causes the polymer to harden precisely at the point where the light hit the surface.

  8. INTRODUCTION TO RAPID PROTOTYPING UNIQUENESS • Resolution • Accuracy • End product is very close to physical model • Very stable and has a good dimensional accuracy.

  9. TYPE & TECHNIQUE OF RAPID PROTOTYPING DISADVANTAGE ? • Water absorprtion into the resin overtime in thin areas will result in curling warping. • System cost is high • Material available only photosensitive resin • Often parts cannot be used for durability and thermal testing • Most cases, parts have not fully cured

  10. TYPE & TECHNIQUE OF RAPID PROTOTYPING Limitation • Parts with enclosed and hollow structures are problems as the liquid may be trapped inside the enclosed body during building • The areas of applications are restricted due to given material properties

  11. TYPE & TECHNIQUE OF RAPID PROTOTYPING SOLID BASED RP PROCESSES

  12. TYPE & TECHNIQUE OF RAPID PROTOTYPING

  13. TYPE & TECHNIQUE OF RAPID PROTOTYPING EXTRUSION BASED PROCESS • Extrusion based process feeds material in solid wire form and then melts it into a shape and form a solid.

  14. TYPE & TECHNIQUE OF RAPID PROTOTYPING FDM • FDM stand for Fused Deposition Modeling is a process was originally developed by Advanced Ceramics Research (ACR ) in Tucson ,Arizona but the advanced by Stratasys. • Non Laser filament extrusion process that utilizes engineering thermoplastics.

  15. TYPE & TECHNIQUE OF RAPID PROTOTYPING PROCESS • The extrusion-based process utilizes filament molten thermoplastic that are extruded from a heated tip to build up layers comprising the physical model.

  16. TYPE & TECHNIQUE OF RAPID PROTOTYPING 5 STEPS • Starting with the filament being fed into drive wheels • The drive wheels force the filament into liquefier • The heater block the filament • The solid filament used as a linear piston • The melted filament is forced through a tip.

  17. TYPE & TECHNIQUE OF RAPID PROTOTYPING

  18. MATERIAL IN 3D PRINTER (FDM) PLA PVA HIPS ABS PLA ABS The two main plastic types used in small scale 3D Printing. These are thermoplastic, able to be heated , molded, and cooled

  19. PLA ( POLYLACTIC ACID ) PLA is a biodegradable thermoplastic aliphatic polyester derived from renewable source such as corn starch Plastic choice for many 3D printer users Easy to use, fast to print, affordable and glossy surface finish Advantage of handling large prints due to its ability to holds its shape while cooling Disadvantage is that susceptible to UV damage and deform under heat ( above 60 degree Celsius )

  20. ABS (ACRYLONITRILE BUTADIENE STYRENE) ABS is a common thermoplastic polymer. Largely used in various application such manufacturing, automotive components Well known for strong, flexible, and durable and it can survive UV,water Great for end-use components and functional parts Disadvantage is that slightly difficult to print from which can result in longer lead times Do not large object effectively as PLA does ( Parts greater than 180mm wide )

  21. PLA ABS Non brittle Heat/Water/UV resistant Used in functional parts Not ideal for large parts Recommend for : Functional end-use parts, Environment resistance Reliable Large Prints Weak to High temperatures Recommend for : Prototypes,props,model

  22. PDT 235 RAPID PROTOTYPING 2

  23. TYPE & TECHNIQUE OF RAPID PROTOTYPING SUPPORT

  24. TYPE & TECHNIQUE OF RAPID PROTOTYPING WHAT SUPPORT DO? • Support structures play an integral role in printing parts • They allow for a wide variety of complex and detailed parts to be printed. • Support structures can be thought of as scaffolding; they allow for construction of parts and are removed afterwards. 

  25. TYPE & TECHNIQUE OF RAPID PROTOTYPING SUPPORT MATERIAL • Selection of material for support is important. • The use of water soluble material is very convenient as it easy to remove those structures. • The ultrasonic based water soluble material is very noisy, and thus should be placed in an isolated room.

  26. TYPE & TECHNIQUE OF RAPID PROTOTYPING REMOVE SUPPORT • Support material may be removed in two different ways. • BASS stands for Break Away Support Structure. • The support is broken away manually and the model is cleaned with sand paper and tools. • WaterWorks is a method that removes the support material automatically in a water based solution.

  27. TYPE & TECHNIQUE OF RAPID PROTOTYPING REMOVING SUPPORT MATERIAL ULTRASONIC TANK ULTRASONIC CLEANING involves the use of high-frequency sound waves (above the upper range of human hearing, or about 18 kHz) to remove a variety of contaminants from parts immersed in aqueous media. It basically a combination of high frequency sound wave and an appropriate cleaning solvent. This technique was used to remove support material from RP part

  28. TYPE & TECHNIQUE OF RAPID PROTOTYPING ADVANTAGE • The extrusion based process is widely used in almost every industry:automotive, aerospace, business, commercial machines, medical, consumer products, architecture • The advantages of the extrusion based process include functional materials, including ABS and medical ABS, investment casting wax and elastromers.

  29. TYPE & TECHNIQUE OF RAPID PROTOTYPING • Does not waste much material during and after producing the part. • It is also easy to use and safe, use inexpensive materials, fits on a desktop, produce non fragile parts and even use water soluble support material.

  30. AUTOMOTIVE MEDICAL AEROSPACE EDUCATION ARCHITECTURE

  31. TYPE & TECHNIQUE OF RAPID PROTOTYPING POWDER BASED RP PROCESSES

  32. TYPE & TECHNIQUE OF RAPID PROTOTYPING • Direct Laser Deposition and laser sintering process belong to the category of powder based RP techniques. • This technique is quite similar except for the type of material used.

  33. TYPE & TECHNIQUE OF RAPID PROTOTYPING POWDER BASED • IN GENERAL : • Principle used is to fuse a powdered material and deposit it on the required region.

  34. TYPE & TECHNIQUE OF RAPID PROTOTYPING LASER SINTERING PROCESSSLS ( SELECTIVE LASER SINTERING ) • 1ST SLS patented in 1989, using laser to bond or sinter powdered material into the solid part. • Similar to SLA process but photosensitive resin is replaced with powdered thermoplastic or high temperature material with thermoplastic binder.

  35. SLS is thermal process that uses a laser to sinter (fuse ) layers of powdered thermoplastic materials together to form solid 3D project.

  36. TYPE & TECHNIQUE OF RAPID PROTOTYPING MATERIAL

  37. TYPE & TECHNIQUE OF RAPID PROTOTYPING

  38. TheSelective Laser Sintering process begins with the conversion of customer generated 3D CAD data into a sliced STL file using proprietary software. Once created the STL file is then sent to print on the Selective Laser Sintering machine. • The machine warms up (with LS material heated to just below melting point) prior to the feed bed rises (typically by <0.1mm) and the levelling roller pushes fresh powder across the build platform/part bed. • The first layer is then traced out by a CO2 laser which melts and fuses the LS material upon contact. Once the first layer has completed the build platform/part bed drops by a pre-set amount. • The feeder bed rises and a fresh layer of powder is swept along the build platform. The next layer is then traced out and the process repeats layer by layer until the model has “fully grown”. • Upon completion the model is left to cool before being removed and any loose material brushed away (as the Selective Laser Sintering process requires no support structures)

  39. TYPE & TECHNIQUE OF RAPID PROTOTYPING • This process offers the key advantage of making functional parts in essentially final material • However the system is mechanically more complex than SLA. • Surface finishes and accuracy are not quite good as with SLA

  40. TYPE & TECHNIQUE OF RAPID PROTOTYPING SUPPORT • No support required with this method since overhangs and under cuts are supported by solid powder bed • Save finishing time compared with SLA or FDM

  41. TYPE & TECHNIQUE OF RAPID PROTOTYPING FINISHING • Since the objects are sintered, they are porous • It may necessary to infiltrate the object with another material to improve mechanical properties.

  42. TYPE & TECHNIQUE OF RAPID PROTOTYPING Example:

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