ME711PE: ADDITIVE MANUFACTURING(PE – II)

UNIT - I
Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping,Advantages and Limitations of Rapid Prototyping,
Commonly used Terms, Classification of RP process,Rapid Prototyping Process Chain: Fundamental Automated Processes
UNIT - II
Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo
polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models
and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Solid-based Rapid Prototyping Systems: Laminated
Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused
Deposition Modeling (FDM): Models and specifications,Process, working principle, Applications, Advantages and Disadvantages, Case studies
UNIT - III
Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications,Process, working principle, Applications, Advantages
and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications,Advantages and
Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT),Conventional Tooling Vs RT, Need for RT. Rapid Tooling Classification; Indirect
Rapid Tooling Methods:Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Diecasting, Sand Casting, 3D Keltool
process. Direct Rapid Tooling : Direct AIM, LOM Tools, DTM RapidTool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP.
UNIT - IV
Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file
Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like
Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor.
UNIT - V
RP Applications: Application - Material Relationship, Application in Design, Application in Engineering,Analysis and Planning, Aerospace Industry,
Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning
and simulation of complex surgery, Customized Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and
Anthropology, Visualization of Biomolecules.
 ME711PE: COMPOSITE MATERIALS (PE – II)
.

TEXT BOOKS:
1. Rapid prototyping; Principles and Applications /Chua C.K., Leong K.F. and LIM C.S/World
Scientific Publications
2. Rapid Manufacturing /D.T. Pham and S.S. Dimov/Springer
 ME711PE:Additive Manufacturing

UNIT - II
Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA):
Models and specifications, Process, working principle, photopolymers, photo
polymerization, Layering technology, laser and laser scanning, Applications, Advantages
and Disadvantages, Case studies. Solid ground curing (SGC): Models and specifications,
Process, working principle, Applications, Advantages and Disadvantages, Case studies
Solid-based Rapid Prototyping Systems: Laminated Object Manufacturing (LOM):
Models and specifications, Process, working principle, Applications, Advantages and
Disadvantages, Case studies. Fused Deposition Modeling (FDM): Models and
specifications,Process, working principle, Applications, Advantages and Disadvantages,
Case studies
Classification of RP
Classification of AM processes

Layered Manufacturing (LM) processes as classified by Pham

CLASSIFICATION OF RAPID PROTOTYPING SYSTEMS

RP systems can be easily categorized into

(1) liquid-based
(2) solid-based and
(3) powder based.
 Liquid-Based

Liquid-based RP systems have the initial form of its material in liquid

state. Through a process commonly known as curing, the liquid is
converted into the solid state. The following RP systems fall into this
category:
(1) 3D Systems’ Stereolithography Apparatus (SLA)
(2) Cubital’s Solid Ground Curing (SGC)
(3) Sony’s Solid Creation System (SCS)
(4) CMET’s Solid Object Ultraviolet-Laser Printer (SOUP)
(5) Autostrade’s E-Darts
(6) Teijin Seiki’s Soliform System
Liquid-Based
(7) Meiko’s Rapid Prototyping System for the Jewelry Industry
(8) Denken’s SLP, (9) Mitsui’s COLAMM
(10) Fockele & Schwarze’s LMS, (11) Light Sculpting
(12) Aaroflex, (13) Rapid Freeze
(14) Two Laser Beams (15) Microfabrication

As is illustrated in the RP Wheel in Figure 1.3, three methods are possible under the
“Photo-curing” method. The single laser beam method is most widely used and include
all the above RP systems with the exception of (2), (11), (13) and (14).
Cubital (2) and Light Sculpting (11) use the masked lamp method,
Two laser beam method is still not commercialized. Rapid Freeze (13) involves the
freezing of water droplets and deposit in a manner much like FDM to create the
prototype.
Classification of AM processes Liquid based RP system

• Liquid-based RP systems have the initial form of its material in liquid state.
• The liquid is converted into the solid state.
• The first commercial system was the 3D Systems Stereolithography process
based on liquid photopolymers.
Liquid based RP system
Classification of AM processes Liquid based RP system

Stereolithography Apparatus (SLA) Process

• 3D Systems was founded in 1986 by inventor Charles W. Hull and entrepreneur

Raymond S. Freed and its first commercial system marketed in 1988.

• It has been awarded more than 40 United States patents and 20 international
patents, with additional patents filed or pending internationally.
 Liquid based RP system
Stereolithography Apparatus (SLA) Process
Principle
The SLA process is based on the following principles

• Parts are built from a photo-curable liquid resin that cures when exposed to a laser
beam (photopolymerization process) which scans across the surface of the resin.
• The building is done layer by layer, each layer being scanned by the optical
scanning system and controlled by an elevation mechanism which lowers at the
completion of each layer.
 Principle
The SLA process is based on the following principles

These two principles will be briefly discussed in this section to lay the
foundation to the understanding of RP processes.
• They are mostly applicable to the liquid-based RP systems.
• This first principle deals mostly with photo-curable liquid resins, which are
essentially photopolymers and the photopolymerization process.
• The second principle deals mainly with CAD data, the laser, and the control
of the optical scanning system as well as the elevation mechanism.
Classification of AM processes
• The following RP systems fall into this category:

• Aaroflex
• 3D Systems’ Stereolithographic Apparatus (SLA)
• Rapid Freeze
• Cubital’s Solid Ground Curing (SGC)
• Two Laser Beams
• Sony’s Solid Creation System (SCS)
• Microfabrication
• CMET’s Solid Object Ultraviolet-Laser Printer (SOUP)
• Fockele & Schwarze’s LMS
• Autostrade’s E-Darts
• Light Sculpting
• Teijin Seiki’s Soliform System
• Denken’s SLP
• Meiko’s Rapid Prototyping System for the Jewelery Industry
• Mitsui’s COLAMM
https://www.youtube.com/watch?v=eKk2vRysioE
Liquid based RP system
Stereolithography Apparatus (SLA) Process

Schematic of SLA process

 Liquid polymer system
Stereolithography Apparatus (SLA) Process
• Stereolithography process creates 3D plastic objects directly from CAD data.

• The process begins with the vat filled with the photo-curable liquid resin and the elevator table

set just below the surface of the liquid resin.

• 3D CAD solid model file is loaded into the system by the operator.

• Supports are designed to stabilize the part during building.

• The translator converts the CAD data into a STL file.

• The control unit slices the model and support into a series of cross sections from 0.025 to 0.5
mm thick.
 Liquid polymer system
Stereolithography Apparatus (SLA) Process
• The optical scanning system directs and focuses the laser beam to solidify a 2D cross-
section corresponding to the slice on the surface of the photo-curable liquid resin.
• The elevator table drops enough to cover the solid polymer with another layer of the
liquid resin.
• A levelling wiper or vacuum blade moves across the surfaces to recoat the next layer of
resin on the surface.
• The laser then draws the next layer.
• The process continues building the part from bottom up, until the system completes the
part.
• The part is then raised out of the vat and cleaned of excess polymer.
 Liquid based RP system
Stereolithography Apparatus (SLA) Process

Applications:
• Models for conceptualization, packaging and presentation.

• Prototypes for design, analysis, verification and functional testing.

• Parts for prototype tooling and low volume production tooling.

• Patterns for investment casting, sand casting and molding.

• Tools for fixture and tooling design, and production tooling.

 CUBITAL’S SOLID GROUND CURING (SGC)

Principle
• Parts are built, layer by layer, from a liquid photopolymer resin that solidifies when exposed to UV light.

• Multiple parts may be processed and built in parallel by grouping them into
batches (runs) using Cubital’s proprietary software.

• Each layer of a multiple layer run contains cross-sectional slices of one or many parts.

• The process is self-supporting and does not require the addition of external support structures to emerging
parts since continuous structural support for the parts is provided by the use of wax, acting as a solid support
material.
 Liquid based RP system
CUBITAL’S SOLID GROUND CURING (SGC)
Principle
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Solid Ground Curing(SGC)
Laminated Object Manufacturing(LOM)