Rapid Prototyping. Andy Fisher Faculty of Engineering and Applied Science Memorial University. Speaking of Engineering St. John s, February 19, 2009
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1 Rapid Prototyping Andy Fisher Faculty of Engineering and Applied Science Memorial University it g St. John s,
2 How do we make complex things?
3 How do we make complex things? Traditionally Subtractive ti processes carving / cutting machining Then Introduction of CAD modeling computer controlled machining (CNC) for mass production create molds through the same techniques and then use injection molding or similar processes.
4 How will we make complex things? So what will the future look like? The trend is away from mass production and pushing the same solution for everyone. The trend is towards mass customization. Maybe someday we ll return to repairing i instead of throwing things away.
5 Maybe a Replicator in every home?
6 Let s look at Rapid Prototyping Replicators may take awhile! RP technology is based on additive processes. Complicated 3D geometry must be simplified in order to facilitate fabrication. What is the secret to this simplification? Planar Slicing! i
7 Rapid Prototyping All complex shapes can be thought ht of as a stack of horizontal slices. Rapid Prototyping technologies all work on this principle, although there are many different approaches to making and bonding the slices. So how does it work?
8 Rapid Prototyping each 3D geometric model is mathematically sectioned into parallel cross-sections. each cross-section creates a 2D binding, curing or cutting path for model construction. Models are constructed one layer at a time until complete. Supports may be required.
9 Rapid Prototyping Two stages: Data preparation and model production. Data Preparation: CAD model is represented in an STL file format. RP software imports STL file and generates slices and custom driving program for the RP hardware.
10 Rapid Prototyping Model Production: many different RP technologies are commercially available. major differences are in material choices and in the build techniques. Let s review some typical systems.
11 STereoLithography
12 Photo Masking
13 Laminated Object Manufacturing
14 Laminated Object Manufacturing (LOM)
15 Laminated Object Manufacturing (LOM)
16 Fused Deposition Modeling (FDM)
17 Rapid Prototyping in Engineering i Engineering Design: RP typically proves form and fit, but not function. RP is used to speed up the design process make mistakes faster! enhances communication with all stakeholders, regardless of technical background. Some examples are:
18 Examples of RP with local industrial i partners.
19 Examples of RP with local industrial i partners.
20 Examples of RP with local industrial i partners.
21 Examples of RP with local industrial i partners.
22 Examples of RP with local industrial i partners.
23 Examples of RP with local industrial i partners. Garrison Guitars
24 Examples of and engineering students. t
25 Examples of RP in the artistic community. Artist: Bathsheba Grossman PROCESS: CAD Drawings, Mathematica, Surface Evolver ExOne.Com: 3D metal printing Each layer is.004" to.007" thick undercuts : no problem heat drives off the binder and fuses the steel powder : 40% air Dipped in bronze: wicks up, then finish
26 Where does it go from here? Rapid Prototyping QuickParts.com, com etc. Rapid Tooling Direct Digital i Manufacturing Desktop Manufacturing Free-Form Fabrication Fab@home????????? How s your imagination?
27 Thanks for your attention. Any Questions?
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