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Questions and Answers
What is the primary purpose of the remaining stock in LOM?
What is a limitation of RP systems in the product definition stage?
Why do users sometimes tilt the object/cluster by 10 to 15 degrees?
What are the four primary areas of Rapid Prototyping development?
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What is the primary cutting tool used in LOM?
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What is the initial form of the material in Liquid-based RP systems?
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What is the primary advantage of using paper in LOM?
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What is the primary purpose of the binder liquid in 3D printing?
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Which of the following RP systems is classified as a Powder-based RP system?
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What is the primary function of the deposition head in the Laser Engineered Net Shaping (LENS) process?
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What is the primary purpose of the twin heads in Fused Deposition Modeling (FDM)?
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What is the purpose of the argon chamber in the Laser Engineered Net Shaping (LENS) process?
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What is the advantage of LENS process in terms of material properties?
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What is the limitation of the LENS process?
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What is the advantage of DMD process?
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What is the limitation of DMD process?
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What is the advantage of 'Paste and then cut' approach in LOM process?
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What is the disadvantage of 'Cut and then paste' approach in LOM process?
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What is the primary goal of organizations in today's fast-paced marketplace?
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What is a prototype?
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What is Rapid Prototyping (RP)?
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What are some alternative names for Rapid Prototyping (RP)?
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What is a limitation of traditional prototyping?
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How do traditional prototyping methods compare to rapid prototyping in terms of time?
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What is the primary mechanism of fusion in Electron Beam Melting (EBM)?
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What is the primary limitation of the Fused Deposition Modeling (FDM) process?
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What is the purpose of the moving x-y nozzle in Fused Deposition Modeling (FDM)?
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What is the primary advantage of Electron Beam Melting (EBM) over laser-based systems?
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What is the primary purpose of the powder in Selective Laser Sintering (SLS)?
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What is the primary advantage of Fused Deposition Modeling (FDM) over other RP processes?
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What is the primary purpose of using an inert environment in the Selective Laser Sintering process?
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What is the purpose of the contra-rotating roller in the Selective Laser Sintering process?
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What is the primary advantage of using Selective Laser Sintering?
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What is the primary limitation of Selective Laser Sintering?
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What is the primary purpose of the laser beam in the Stereo Lithography process?
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What is the primary purpose of the post-cure apparatus in the Stereo Lithography process?
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What is the primary advantage of using Stereo Lithography?
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What is the primary limitation of Stereo Lithography?
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What is the primary purpose of the beam in the Selective Laser Sintering process?
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What is the primary purpose of the copper impregnation in the Selective Laser Sintering process?
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Study Notes
Introduction to Rapid Prototyping
- Rapid prototyping (RP) is a class of technologies that create physical models from Computer-Aided Design (CAD) data.
- Alternative names for RP include Additive Manufacturing, Layer Manufacturing, Direct CAD Manufacturing, and Solid Freeform Fabrication.
Traditional Prototyping vs. Rapid Prototyping
- Traditional prototyping involves building a model from clay, carving from wood, bending wire, or using thermoplastic, photopolymer, metals, paper, or titanium alloys.
- Traditional prototyping methods are time-consuming, lack quality, and cannot effectively evaluate alternative design concepts.
- Rapid prototyping methods are faster, more accurate, and can effectively evaluate design concepts.
Classification of Rapid Prototyping Systems
- RP systems can be classified into three categories: liquid-based, solid-based, and powder-based.
Liquid-Based RP Systems
- Liquid-based RP systems include:
- 3D Systems' Stereo lithography Apparatus (SLA)
- Cubital's Solid Ground Curing (SGC)
- Sony's Solid Creation System (SCS)
- CMET's Solid Object Ultraviolet-Laser Printer (SOUP)
- Autostrade's E-Darts
- Teijin Seiki's Soliform System
- Meiko's Rapid Prototyping System for the Jewelry Industry
- Denken's SLP
- Mitsui's COLAMM
- Fockele & Schwarze's LMS
- Light Sculpting
- Aaroflex
- Rapid Freeze
- Two Laser Beams
- Micro fabrication
Additive Manufacturing Techniques
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- Laser Engineered Net Shaping (LENS)
- Builds components in an additive manner from powdered metals using a Nd:YAG laser.
- Produces fully dense metal parts with good metallurgical properties.
- Advantages: superior material properties, complex parts, and reduced post-processing requirements.
- Disadvantages: limited materials, large physical unit size, and high power consumption.
-
- Direct Metal Deposition (DMD)
- Uses a laser to weld air-blown streams of metallic powders into custom parts.
- Can produce fully dense metal parts with good metallurgical properties.
- Advantages: ability to fabricate fully dense metal parts, efficient, and reduces production costs.
- Disadvantages: limited to building overhang parts and requires support structures.
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- Sheet Lamination (Laminated Object Manufacturing (LOM)
- Builds parts by laminating layers of paper or other materials.
- Advantages: fast, inexpensive, and ideal for patterns for casting.
- Limitations: grid cutting takes time, decubing is time-consuming, and horizontal surfaces pose problems.
-
- 3D Printing
- Similar to SLS, except that a binder liquid is sprayed in selected regions.
- Can use a wide variety of powders.
- Advantages: fast, inexpensive, and ideal for concept models.
- Limitations: requires sintering, and supports are required.
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- Fused Deposition Modeling (FDM)
- Uses molten material to build parts.
- Advantages: uses any thermoplastic material, easy to remove support, and inexpensive.
- Limitations: slow, not very accurate, and requires explicit support structures.
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- Electron Beam Melting (EBM)
- Uses an electron beam to induce fusion between metal powder particles.
- Advantages: fast, efficient, and can process conductive materials.
- Limitations: can only be used with conductive materials, and has a larger heat-affected zone.
-
- Selective Laser Sintering (SLS)
- Uses a laser to fuse together metal powder particles.
- Advantages: fast, uses a wide variety of powders, and ideal for making injection molding tools.
- Limitations: surface finish is poor, and Z accuracy is poor.
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- Photopolymerization (Stereo Lithography (SLA)
- Uses a laser to polymerize liquid photopolymer.
- Advantages: fast, accurate, and ideal for making prototypes.
- Limitations: requires explicit support structures, and post-processing is required.
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Description
Learn about Rapid Prototyping (RP), a technology that creates physical models from CAD data, and its differences with traditional prototyping methods.
