Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Chapter 20Rapid-Prototyping Operations

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Parts Made by Rapid-Prototyping

(a)

(b)

(c)

Figure 20.1 Examples of parts made by rapid-prototyping processes: (a) selection ofparts 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.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Characteristics of Additive Rapid-Prototyping Technologies

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Mechanical Properties of Selected Materials for RapidPrototyping

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

ComputationalSteps in Rapid

Prototyping

Figure 20.2 Thecomputational steps inproducing a stereolithographyfile. (a) Three-dimensionaldescription 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 isdetermined to manufactureeach slice. Also shown is theextruder path at section A-Afrom (c) for a fused-deposition-modeling operation.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Fused-Deposition-Modeling

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

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

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.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Stereolithography

Figure 20.5 Schematic illustration of the stereolithography process.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

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.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

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.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

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.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Three-Dimensional-Printing to Produce Metal Parts

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

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Fuselage Fitting Made by Three-Dimensional-Printing

(a)

(b)

Figure 20.10 A fitting required for a helicopter fuselage. (a) CAD representation with addeddimensions. (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.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Laminated-Object-Manufacturing

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

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Invisalign OrthodonticAligners

(a) (b)

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

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Manufacturing of InvisalignOrthodontic Aligners

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

(a)

(b)(c)

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

Investment Casting Using Rapid-Prototyped Wax Parts

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

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

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.