Slide 1

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Chapter 20

Rapid-Prototyping Operations

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Parts Made by Rapid-Prototyping

(a)

(b)

(c)

Figure 20.1  Examples of parts made by rapid-prototyping processes:  (a)
selection of parts from fused-deposition modeling; (b) stereolithography model
of cellular phone; and (c) selection of parts form three-dimensional printing.
Source:  Courtesy of Stratasys, Inc., (b) and (c) Courtesy of 3D Systems, Inc.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Characteristics of Additive Rapid-Prototyping

Technologies

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Mechanical Properties of Selected Materials for

Rapid Prototyping

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Computational

Steps in Rapid

Prototyping

Figure 20.2  The
computational steps in
producing a
stereolithography file.  (a)
Three-dimensional
description of each part.
(b)  The part is divided into
slices (only one in 10 is
shown).  (c)  Support
material is planned.  (d)  A
set of tool directions is
determined to
manufacture each slice.
Also shown is the extruder
path at section A-A from
(c) for a fused-deposition-
modeling operation.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Fused-Deposition-Modeling

Figure 20.3 (a) Schematic illustration of the fused-deposition-modeling process.
(b) The FDM 5000, a fused-deposition-modeling machine. Source: Courtesy of
Stratysis, Inc.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Support Materials and Structures in Parts

Figure 20.4  (a)  A part with a protruding section which requires support
material.  (b)  Common support structures used in rapid-prototyping
machines.  Source:  P. F. Jacobs, Rapid Prototyping & Manufacturing:
Fundamentals of Stereolithography.  Society of Manufacturing Engineers,
1992.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Stereolithography

Figure 20.5 Schematic illustration of the stereolithography
process.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Two-Button Computer Mouse

Figure 20.6 A two-button computer
mouse. Source: Courtesy of 3D Systems,
Inc.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Selective-Laser-Sintering

Figure 20.7 Schematic illustration of the selective-laser-sintering
process. Source: After C. Deckard and P. F. McClure.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Three-Dimensional-Printing

Figure 20.8 Schematic illustration of the three-dimensional-printing
process. Source: After E. Sachs and M. Cima.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Three-Dimensional-Printing to Produce Metal Parts

Figure 20.9  Three-dimensional-printing using (a) part-build, (b) sinter, and (c)
infiltration steps to produce metal parts.  (d)  An example of a bronze-infiltrated
stainless-steel part produced through three-dimensional printing.  Source:
Courtesy of ProMetal.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Fuselage Fitting Made by Three-Dimensional-

Printing

(a)

(b
)

Figure 20.10  A fitting required for a helicopter fuselage.  (a) CAD representation
with added dimensions.  (b)  Dies produced by three-dimensional printing.  (c)
Final forged workpiece.  Source:  Courtesy of ProMetal.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Laminated-Object-Manufacturing

Figure 20.11  (a)  Schematic illustration of the laminated-object-
manufacturing process.  (b)  Crankshaft-part examples made by LOM.
Source:  (a)  Courtesy of Helsis, Inc.  (b)  After L. Wood.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Invisalign

Orthodontic

Aligners

(a
)

(b)

Figure 20.12  (a) An aligner for orthodontic use manufactured using a
combination of rapid tooling and thermoforming.  (b)  Comparison of
conventional orthodontic braces to the use of transparent aligners.  Source:
Courtesy of Align Technologies, Inc.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Manufacturing of

Invisalign Orthodontic

Aligners

Figure 20.13  The manufacturing sequence for Invisalign orthodontic aligners.  (a)
Creation of a polymer impression of the patient’s teeth.  (b)  Computer modeling
to produce CAD representations of desired tooth profiles.  (c)  Production of
incremental models of desired tooth movement.  An aligner is produced by
thermoforming a transparent plastic sheet against this model.  Source:  Courtesy
of Align Technologies, Inc.

(a)

(b)

(c)

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Investment Casting Using Rapid-Prototyped Wax

Parts

Figure 20.14  Manufacturing steps for investment casting that uses rapid-
prototyped wax parts as blanks.  This method uses a flask for the investment,
but a shell method also can be used.  Source:  Courtesy of 3D Systems, Inc.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.

Rapid Tooling for a Rear-Wiper Motor Cover

Figure 20.15 Rapid tooling for a rear-wiper motor
cover. Source: Courtesy of 3D Systems, Inc.

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