Introduction to Rapid Prototyping
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What is the primary purpose of the remaining stock in LOM?

  • To improve the overall appearance of the part
  • To reduce the time required for decubing
  • To create a strong bond between layers
  • To act as a support material (correct)

    • What is a limitation of RP systems in the product definition stage?

  • Increases product launch time
  • It can't effectively evaluate the alternative design concepts (correct)
  • It can effectively evaluate the alternative design concepts
  • Reduces product launch time

    • Why do users sometimes tilt the object/cluster by 10 to 15 degrees?

  • To increase the strength of the part
  • To improve the overall appearance of the part
  • To avoid any surface becoming horizontal (correct)
  • To reduce the time required for decubing

    • What are the four primary areas of Rapid Prototyping development?

    <p>Input, Method, Material, Applications</p> Signup and view all the answers

    What is the primary cutting tool used in LOM?

    <p>CO2 laser</p> Signup and view all the answers

    What is the initial form of the material in Liquid-based RP systems?

    <p>Liquid</p> Signup and view all the answers

    What is the primary advantage of using paper in LOM?

    <p>It is very cheap</p> Signup and view all the answers

    What is the primary purpose of the binder liquid in 3D printing?

    <p>To make the particles in the powder stick together</p> Signup and view all the answers

    Which of the following RP systems is classified as a Powder-based RP system?

    <p>Selective laser sintering (SLS)</p> Signup and view all the answers

    What is the primary function of the deposition head in the Laser Engineered Net Shaping (LENS) process?

    <p>To supply metal powder to the focus of the laser</p> Signup and view all the answers

    What is the primary purpose of the twin heads in Fused Deposition Modeling (FDM)?

    <p>To create explicit support structures</p> Signup and view all the answers

    What is the purpose of the argon chamber in the Laser Engineered Net Shaping (LENS) process?

    <p>To provide oxygen-free operation</p> Signup and view all the answers

    What is the advantage of LENS process in terms of material properties?

    <p>Produces fully dense metal parts</p> Signup and view all the answers

    What is the limitation of the LENS process?

    <p>It is currently limited to produce only metal parts</p> Signup and view all the answers

    What is the advantage of DMD process?

    <p>It produces fully dense metal parts with good metallurgical properties</p> Signup and view all the answers

    What is the limitation of DMD process?

    <p>It has a limit to the overhang angle that can be built</p> Signup and view all the answers

    What is the advantage of 'Paste and then cut' approach in LOM process?

    <p>Handling is easy</p> Signup and view all the answers

    What is the disadvantage of 'Cut and then paste' approach in LOM process?

    <p>Handling is difficult</p> Signup and view all the answers

    What is the primary goal of organizations in today's fast-paced marketplace?

    <p>To respond quickly to changing customer demands</p> Signup and view all the answers

    What is a prototype?

    <p>A model from which further models and eventually the final product will be derived</p> Signup and view all the answers

    What is Rapid Prototyping (RP)?

    <p>A process for rapidly creating a system or part representation before final release or commercialization</p> Signup and view all the answers

    What are some alternative names for Rapid Prototyping (RP)?

    <p>Additive Manufacturing, Layer Manufacturing, and Direct CAD Manufacturing</p> Signup and view all the answers

    What is a limitation of traditional prototyping?

    <p>It lacks the quality to serve its purpose</p> Signup and view all the answers

    How do traditional prototyping methods compare to rapid prototyping in terms of time?

    <p>Rapid prototyping is faster</p> Signup and view all the answers

    What is the primary mechanism of fusion in Electron Beam Melting (EBM)?

    <p>Transfer of kinetic energy from incoming electrons into powder particles</p> Signup and view all the answers

    What is the primary limitation of the Fused Deposition Modeling (FDM) process?

    <p>It is very slow</p> Signup and view all the answers

    What is the purpose of the moving x-y nozzle in Fused Deposition Modeling (FDM)?

    <p>To deposit material in a specific pattern based on a CAD model</p> Signup and view all the answers

    What is the primary advantage of Electron Beam Melting (EBM) over laser-based systems?

    <p>It is more efficient in generating the energy beam</p> Signup and view all the answers

    What is the primary purpose of the powder in Selective Laser Sintering (SLS)?

    <p>To be sintered together to form the final part</p> Signup and view all the answers

    What is the primary advantage of Fused Deposition Modeling (FDM) over other RP processes?

    <p>It is the easiest to remove the support material</p> Signup and view all the answers

    What is the primary purpose of using an inert environment in the Selective Laser Sintering process?

    <p>To minimize fire hazards due to the high activation of fine particles</p> Signup and view all the answers

    What is the purpose of the contra-rotating roller in the Selective Laser Sintering process?

    <p>To spread and level the powder</p> Signup and view all the answers

    What is the primary advantage of using Selective Laser Sintering?

    <p>It is suitable for making injection molding tools</p> Signup and view all the answers

    What is the primary limitation of Selective Laser Sintering?

    <p>The surface finish is less and dictated by the particle size</p> Signup and view all the answers

    What is the primary purpose of the laser beam in the Stereo Lithography process?

    <p>To scan the layer of liquid photopolymer</p> Signup and view all the answers

    What is the primary purpose of the post-cure apparatus in the Stereo Lithography process?

    <p>To complete the polymerization of the part</p> Signup and view all the answers

    What is the primary advantage of using Stereo Lithography?

    <p>It is a fast process due to the use of tiny moving mirror parts</p> Signup and view all the answers

    What is the primary limitation of Stereo Lithography?

    <p>It requires explicit support structures</p> Signup and view all the answers

    What is the primary purpose of the beam in the Selective Laser Sintering process?

    <p>To scan the layer of powder</p> Signup and view all the answers

    What is the primary purpose of the copper impregnation in the Selective Laser Sintering process?

    <p>To improve the polishability of the metallic prototypes</p> Signup and view all the answers

    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

      1. 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.
      1. 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.
      1. 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.
      1. 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.
      1. 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.
      1. 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.
      1. 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.
      1. 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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    Learn about Rapid Prototyping (RP), a technology that creates physical models from CAD data, and its differences with traditional prototyping methods.

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