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fre_rapid p+t_eng_2003-03.ppt- 1
Fraunhofer InstitutProduktionstechnologie
IPT
Rapid Prototyping and Rapid Tooling
Prof. Dr.-Ing. Fritz KlockeDipl.-Ing. Carsten Freyer
Fraunhofer Institute for Production Technology IPTSteinbachstraße 17D-52074 Aachen
Email: [email protected]: http://www.ipt.fraunhofer.de
Fraunhofer Institute for Production Technology IPT
2003-03
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Fraunhofer InstitutProduktionstechnologie
IPT
Contents
Legende
Rapid Prototyping and Rapid Tooling
Introduction
RP and RT in product development
Economic aspects
Overview about systems and technologies
Examples of application
Future and perspectives
Conclusions
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IPT
Problem and intention
Situation– Reduction of product development time forced by
innovation pressure and market competition
– Increase of product complexity
– Despite of Virtual Reality tools need for physicalmodels
– Time-consuming conventional, often also manual,model making
Solution– Development of techniques for generative production
of prototypes directly from CAD-data
– Mobilizing of adjacent time and cost advantages
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Rapid Prototyping and Rapid Tooling – definitions
– Generative (layer-by-layer) build up of parts directlyfrom CAD-data
– Usually no molds or tools required
– Accessing of high economic potentials whileproducing complex geometries in small batches
– Same principles and characteristics as for RapidPrototyping
– Layer-by-layer build up of molds and dies (direct RT)
– Shaping of molds and dies from RP-made masterpatterns (indirect RT)
Rapid Prototyping (RP)
Rapid Tooling (RT)
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IPT
Contents
Legende
Rapid Prototyping and Rapid Tooling
Introduction
RP and RT in product development
Economic aspects
Overview about systems and technologies
Examples of application
Future and perspectives
Conclusions
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IPT
Key factor »Time to Market« I/II
Product development time
acc. to: Gebhardt et al.
– Boundary conditions during product developmentprocess:
• Non-concrete or quickly changing customer’sdemands
• Growing importance of design andindividualization
• Environmental aspects• Decreasing product lifetime• Falling prices and cost pressure• Law-enforced boundaries and standards
– Often more than 25% of product development timeare spent for manufacture of prototypes and models
– Delays in market maturity lead to over-proportionalprofit reduction compared to other cost factors
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IPT
Key factor »Time to Market« II/II
acc. to: Gebhardt et al.
Costs– Most of the later costs
are defined in a veryearly stage of productdevelopment cycle
Conclusion– Models, prototypes and
patterns have to beavailable in a very shorttime to guarantee asuccessful product
Determined costs
Project phase
Start ofproduction-
Planning Concep-tion
Development
100 % Share of project costs
75 %
50 %
25 %
0 %
Occured costs
Idea Develop./pro-duction ofmanufac-turing aids
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Needs for prototypes during product developmentPD phase
Type of prototype
Primary demands
Material
Productionmethod
Numbers needed
idea pre-development
design
optical andhaptic
usually modelmaking
manual/modelmaking
1
functionaltesting
functional
funktional/geometrical
model mak./near serial
manual/model/making
2-5
prototypephase
technical
near seriessimul. of allproperties
near series
near serieswith preser.series tools
3-20
Pre seriesphase
pre series
identical toseries simul.of all prop.
serial
series tools
up to 500
Marketintroduction
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IPT
Use of RP models by branches
Source: Wohlers Associates Inc., 2002
Military
Others
Aerospace
Academic institutions
Medical
Business machines
Automotive
– Consumer products andautomotive are taking morethan 50% of RP-modelsproduced
– Increasing trend in medicalareas
– »others«: sporting goods, nonmilitary marine use, ...
Data based on a survey to 16system manufacturers and 47 RP-service providers
Consumer products
0 % 10 % 20 %5 % 25 %15 %
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Use of RP models by application
Source: Wohlers Associates Inc., 2002
Data based on a survey to 16system manufacturers and 47 RP-service providers 0 % 10 % 20 %5 % 15 %
Functional models
Fit/assembly
Visual aids for engineering
Patterns for prototype tooling
Patterns for cast metal
Visual aids for toolmakers
Proposal/quoting
Ergonomic studies
Direct tooling inserts
Other
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IPT
Contents
Legende
Rapid Prototyping and Rapid Tooling
Introduction
RP and RT in product development
Economic aspects
Overview about systems and technologies
Examples of application
Future and perspectives
Conclusions
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IPT
RP-/RT-system installations worldwide
Source: Wohlers Associates Inc., 2002
Units / year
Cumulative sales
Data for 2002 and 2003 estimated
0
250
500
750
1000
1750 units / year
´88 ´89 ´90 ´91 ´92 ´93 ´94 ´95 ´96 ´97 ´98 ´99 ´00 ´01 ´02
0
7500
10000
12500
15000
17500 units cumulative
1250
1500
5000
2500
´03
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Worldwide revenues of RP-/RT-branch
Source: Wohlers Associates Inc., 2002
0
100
200
300
400
500
600
´93 ´94 ´95 ´96 ´97 ´98 ´99 ´00 ´01 ´02
700 Mio. US$
´03
services
products
Data for 2002 and 2003 estimated
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IPT
Ranking of the most important RP-/RT-systems
Source: Wohlers Associates Inc., 2002
0
1000
SL(3D Systems
et al.)
SLS(EOS, 3DSystemset al.)
FDM(Stratasys)
LOM(Helisyset al.)
MJM(3D Systems)
Genisys(Stratasys)
3DP(Z Corp.)
ModelMaker(Solidscape)
3178 7241859 727781 749 519 475
2000
3000 installed systems
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IPT
Contents
Legende
Rapid Prototyping and Rapid Tooling
Introduction
RP and RT in product development
Economic aspects
Overview about systems and technologies
Examples of application
Future and perspectives
Conclusions
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IPT
History– Worldwide first RP-technology at all– Patented 1984– Commercialized 1988 by 3D-Systems Inc.
The generative approach– Production of parts by addition of material instead of
removal (like for example by cutting, ...)– Layer-by-layer build up »bottom-to-top«– Easy manufacture of undercuts, complex structures,
internal holes, ...
Realization by Stereolithography– Local solidification of a light-sensitive liquid resin
(photopolymer) using an UV-Laser– Scanning of the cross-section areas to be hardened
with the laser focus
Stereolithography model
Stereolithography (SL) as example for generative model making
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IPT
Schematic layout of a Stereolithography machine
Main components– Exposure system
– Vat with liquidphotopolymer
– Table with z-drive
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Process principle of Stereolithography
Process steps– Lowering of table by the
thickness of one layer– Application/leveling of
liquid resin– Scanning with Laser– Again lowering of table
Supports– Needed for manufacture
of undercuts– Build up with part similar
to a honey-bee-structure
Simplified animation of SL-process
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IPT
Process chain of Stereolithography I/II
CAD-Model
– 3D CAD-datamust be available
Triangulation
– Conversion into»STL-data«
– Representation ofsurfaces by smalltriangles
– Orientation ofgeometry to themachine’sworkspace
Supports
– Generation ofsupport data
– Will be built uptogether withpart
– »Honey-bee-structure« foreasy removal
Slicing
– Slicing of part’sgeometry andsupport data intolayers
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Process set-up
– Data transfer tomachine
– Setting-up of job– Start of building
process
Production
– Layer-by-layerexposure ofgeometry
Cleaning/Finishing
– Taking out of part– Cleaning of excess
resin– Removal of
supports– Surface finish (if
required)
Post curing
– Final curingunder UV-light
Process chain of Stereolithography II/II
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IPT
System’s overview: Stereolithography (SL)Process principle– Layer-by-layer curing of a liquid
photopolymer by a laser– Control of laser by a scan-mirror
system
Characteristics– High part complexity– High accuracy– Support structure required
Materials– Only photopolymer of different
qualities available (temp.-proof,flexible, transparent, ...)
Max. part size & accuracy– Part size: 250x250x250 mm³ to
1000x800x500 mm³– Accuracy: 0.05 mm
Facility costs– 50 000 - 605 000 US$
Process principle
Functional model »binocular«
Stereolithography facility
Geom. prototype »exhaust pipe«
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IPT
System’s overview: Solid Ground Curing (SGC)Process principle– Layer-by-layer curing of a liquid
photopolymer through a maskby an UV-lamp
– Exposure of each layer in onestep
Characteristics– High complexity– Support realized by wax, no
extra construction necessary– Very complex machine layout
Materials– Only photopolymers
Max. part size & accuracy– Part size: 500x300x500 mm³– Accuracy: 0.1 mm
Facility costs– Approx. 324 000 US$
SGC-machineProcess principle
SGC-part »helmet«
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IPT
System’s overview: Laminated Object Manufacturing (LOM)
Bildquelle: BMT, GOM mbH
Process principle– Laminating and cutting of self-
adhesive foils
Characteristics– Limited part complexity
(removal of inner parts inhollow areas)
– No support required– Wood-like properties when
working with paper
Materials– Paper (but also plastics, metal,
ceramic)
Max. part size & accuracy– Part size: 813x559x508 mm³– Accuracy: +/-0.25 mm
Facility costs– 55 000 - 278 000 US$
Process principle LOM-Machine during process
Removal of excess material LOM model of a car
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IPT
System’s overview: Selective Laser Sintering (SLS, DMLS) I/IIProcess principle– Local melting/sintering of a
powder by a laser– Direct: the powder particles melt
together– Indirect: the powder particles are
coated with a thermoplasticbinder which melts up
Characteristics– High part complexity– Many materials available– Burning out of the binder and
infiltration might be required– Relatively high porosity and
surface roughness– Usually no supports needed
Process principle SLS of plastics: computer mouse
SLS of sand: core for sand casting(EOSINT-S machine, EOS GmbH)
SLS of metals: injection moldinginserts
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System’s overview: Selective Laser Sintering (SLS, DMLS) II/II
Source: EOS GmbH, http://www.eos-gmbh.de/
Materials– Wax– Thermoplastics– Metal– Casting sand– Ceramics
Max. part size & accuracy– Part size: 250x250x150 to
720x500x450 mm³– Accuracy: +/-0.1 mm
Facility costs– 275 000 - 850 000 US$
SLS: Process video and animation (sequences of film material fromEOS GmbH about EOSINT-M and -S machines)
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System’s overview: Fused Deposition Modeling (FDM)
Source: alphacam
Process principle– Melting of a wire-shaped plastic
material and deposition with axy-plotter mechanism
Characteristics– Limited part complexity– Two different material for part
and support
Materials– Thermoplastics (ABS, Nylon,
Wax, ...)
Max. part size & accuracy– Part size: 600x500x600 mm³– Accuracy: +/-0.1 mm
Facility costs– 66 500 - 290 000 US$
FDM - Head
Nozzle
Support Build table
Part
Liquifier
Motor
Wire coil
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IPT
System’s overview: Genisys™Process principle– Extrusion of molten plastic
through a nozzle system (similarto FDM)
Characteristics– Material supply in tablets– Support generated from same
material as part with perforatedconnections
– Office-suited concept modeler
Materials– Polyester
Max. part size & accuracy– Part size: 203x203x203 mm³– Accuracy: +/-0.3 mm
Facility costs– Approx. 45 000 US$
Source: alphacam
Support
Nozzle
Material cassette
Part
Extruder
Motor
Feeder
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System’s overview: ModelMaker™
Source: BMT
Process principle– Application of molten wax using
an ink jet– Cutting of each layer for
constant z-level– Two materials for part and
support
Characteristics– High precision– Geom. Prototypes, Master
patterns for Investment casting
Materials– Wax
Max. part size & accuracy– Part size: 305x152x229 mm³– Accuracy: 0.02 mm
Facility costs– Approx. 67 000$
Process principle
Inkjets
Support
Cutting roll
Object
Machine at work
Parts (green) and Support (red)Wax patterns for investment casting
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System’s overview: Multi-Jet Modeling (MJM)Process principle– Layer-by-layer deposition of
molten plastic droplets using aline of piezoelectric ink jets
Characteristics– Designed as 3D-network-printer
for concept models
Materials– Thermopolymer based on
Paraffin
Max. part size & accuracy– Part size: 250x190x200 mm³– Resolution 400x300 dpi in
x-y-direction
Facility costs– Approx. 50 000 $
Process principle
Model of a UHF receiver
Machine layout
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System’s overview: Three Dimensional Printing (3DP) I/IIProcess principle– Local bonding of starch powder
by a binder using an ink jet(patent of MIT)
Characteristics– Very high building speeds– Easy handling– Binder available in differ. colors– Infiltration necessary– Ideal for fast visualization
Materials– Starch powder (Z Corp.)– Other manufactures offer systems
for ceramics or metal
Max. part size & accuracy– Part size: 200x250x200 mm– Resolution 600 dpi in x-y-direction
Facility costs– 49 000 - 67 500 $
Source: 4D Concepts
Process principle 3DP facility
Model of a mobile phone withcolors based on FEM-analysis
Visualization model of a pump
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IPT
System’s overview: Three Dimensional Printing (3DP) II/IIVideo sequence of3DP-process
Source: 4D Concepts
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System’s overview: Laser generatingProcess principle– Local melting of metal powders
or wire using a laser
Characteristics– Parts have properties close to
serial parts– Surfaces need post processing– Also suited for repair purposes
Materials– Stainless steel, Titanium, special
alloys
Max. part size & accuracy– Part size: 460x460x1070 mm– Accuracy: +/- 0.5 mm
Facility costs– 440 000 - 640 000 $
Source: Lulea Tekn. Univsity,Optomec, Inc., Fraunhofer IPT
Process principle
Laser generated insert for inj. mol-ding (Optomec LENS™ Technology)
Sample parts (Fraunhofer IPT)
Laser focus and powder nozzle
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IPT
Combination of techniques: plastic vacuum moldingProcess principle– Casting of a (RP)-master pattern
in silicon and reproduction
Characteristics– Very detailed reproduction– Undercuts are possible– Silicon mold can be used several
times– Suited for small lots <50
Materials– Various reaction resins– Properties comparable to
numerous plastics
Max. part size & accuracy– Max. part size:
Approx. 1000x1000x2000 mm³– Accuracy depend. from master
Facility costs– 25 000 to 250 000 US$
Housing for drilling machine
Process chain of vacuum molding1 Master pattern2 Casting with silicon under
vacuum3 Cutting of of mold in parting
plane4 Vacuum casting with reaction
resin5 Curing under heat6 Removal of model
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Fast production of injection molding tools
Motivation– Requirements to parts (material, production process,
amount of shots, ...)– Production with serial process
Problems– High efforts in tool making
• Complexity of geometry• Cutting• EDM
– Performance and amount of time/moneydisproportionate to demands of pre-series
Solution– Making of tools and inserts using RP– Direct and indirect approaches– Opening of cost and time potentials
Conventionally made tool inserts
Laser sintered tool inserts
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IPT
Overview about manufacturing techniques for inj. molding toolsabrasive techniques
cutting techniques
milling
3-axis5-axis
turningdrillinggrinding/polishing
SPM (Space Puzzle Molding)
erosive techniques
EDM
sinking EDMmilling EDMwire EDM
ECM
casting techniques
with master
direct
investment castingsandformsKeltooling
indirect
vacuum castingMCP toolKeltooling
without master
PU-GFK
SLS sand
Legend:establishedavailableunder development
Rapid Tooling
powder
direct (EOS)indirect (DTM)
laser generatingLENS (Laser Engineered Net Shaping)CMB (Controlled Metall Build Up)SDM (Shape DepositionManufacturing)FPM (Freeform Powder Molding)
SLS-metal
3D-printing (metal)
foil/sheet metal
Laminated ToolingLOM (metal)Conveyed-adherent Autofab
others
Stereolithography tool
LOM-paper
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Closeness to serial parts and recommended amount of parts forvarious RP/RT approachesPart properties– Surface quality– Form and dimensional
accuracy– Mechanical properties
(stiffness, density, ...)– Physical properties
(thermal, ...)
Non
-iden
t. t
o se
ries
Iden
tical
to
serie
s
Batch number
Part
pro
per
ties
0 10 102 103 104 105
SLS
SL
FDM
MCP-tool
Vacuum-cas.
PU-GFK
SLS (CuNi)
SL-tool
Al-moldSLS (steel)
Steel tool
Keltool ™
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Rapid Tooling: Keltool™Process principle– Duplicate molding of SL-master
patterns by longtime-low temp-sintering
Characteristics– Very high hardness, stiffness and
surface quality– Process chain takes two weeks
Material– Tool steel/Wolframcarbide-
mixture infiltrated with copper
Max. part size & accuracy– Max. size.: 150x215x120 mm³– Tolerance +/-0.2%
Facility costs– System price approx. 200 000 US$– License fee 57 500 US$ / year for 5
years, 172 500 US$ for 1st year Tool inserts
Process chain of Keltool™-process1 Master pattern2 Silicon casting3 Casting with a tool steel/Wolf-
ramcarbide/epoxy mixture4 Burn-out of binder, sintering
and infiltration with copper inan oven
5 Tool insert ready for production
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Rapid Tooling: Indirect Metal Laser Sintering (RapidTool™-process)Process principle– Indirect selective laser sintering
of metal powders– Burning out of binder and
infiltration with copper
Characteristics– Production of tool inserts for
injection molding and diecasting
– Tool life up to 50 000 shots
Materials– Approx. 60% steel and 40%
copper
Max. part size & accuracy– Max. size.: 380x330x447 mm³– Accuracy: +/- 0.1 mm
Facility costs– 275 000 US$ Tool insert
Process chain of RapidTool™technology1 SLS of a polymer-coated steel
powder2 Burning out of binder and
infiltration with copper3 Polishing and insertion into tool
frame
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Rapid Tooling: Direct Metal Laser Sintering (DirectTool™-process)
Source: Fraunhofer IPT in cooperation with Robert Bosch GmbH
Process principle– Direct SLS of powder particles
(DMLS)
Characteristics– Production of tool inserts for
injection molding and diecasting
– No burn-out of binder required,advantages in accuracy and time
Materials– Steel or bronze nickel,
infiltration with epoxy possible
Max. part size & accuracy– Max. size.: 250x250x150 mm³– Accuracy: +/- 0.1 mm
Facility costs– Approx. 320 000 US$
DMLS-insert in tool frame
Process chain of DirectTool™technology1 SLS of metal powder (directly)2 Bronze nickel powder:
infiltration with copperSteel: not necessarily required
3 Polishing and insertion into toolframe
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Rapid Tooling: Controlled Metal Build Up (CMB)Process principle– Layer-by-layer build up of parts
in a combination of laserdeposition welding and HSC
Characteristics– Production and repair of tool
inserts for injection molding anddie casting
– Intermittent cutting allowssmall cutter diameters to beused
– Surfaces in cutting quuality
Materials– Steel
Max. part size & accuracy– Workspace: 600x600x600 mm³– Accuracy: +/- 0.02 mm
Facility costs– Estimated approx. 300 000 EUR
laser welding
base material
weldingwire
laser beam
surface milling
contour milling
inert gas
surface and contour milling
process
injection molding tool with parts
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IPT
Inhalt
Legende
Rapid Prototyping and Rapid Tooling
Introduction
RP and RT in product development
Economic aspects
Overview about systems and technologies
Examples of application
Future and perspectives
Conclusions
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IPT
Examples of application: computer mouseApproach– Manual design of a 1st model– 3D-scanning and import of data
to CAD-system– Production of two shells using
Stereolithography– Construction of inner geometry– Production of a technical
prototype usingStereolithography
– Manufacture of a functionalprototype using SLS
– Optimization of construction– Production of a pre series tool
using SLS of metal– Injection molding of mouse
housings
Design and SL-models SLS prototype (polyamide)
Laser sintered injection moldinginserts
Pre series production
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Examples of application: miniature collector’s car modelsApproach– Import of CAD-data– Data processing and production
of a SL master model– Reproduction by silicon vacuum
casting– Manual modeling of model-/scale-
specific details– Copy-milling of die casting
tool/EDM electrodes CAD-data Stereolithography model
Manual post-processing (example) Final collector’s model
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Examples of application: medical businessBackground– Preparation of medical operations– Detailed representation of
surrounding areas prior to amedical engagement
– Education, visualization
Approach– Gaining of data by
computertomography (CT)– Data processing and model
production
Stereolithography model of a human brain
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IPT
Contents
Legende
Rapid Prototyping and Rapid Tooling
Introduction
RP and RT in product development
Economic aspects
Overview about systems and technologies
Examples of application
Future and perspectives
Conclusions
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Trends and perspectives I/II
Source: 4DConcepts
3DP-Model of a pump station
Tendencies for Rapid Prototyping technologies– »Personal Modelers«– 3D-printers for concept models– Rapid Prototyping for complex models with high
demands regarding materials– Rapid Tooling– Rapid Manufacturing
3D-Printing– Reduction of purchasing and running costs– Systems improvent
• Accuracy• Handling• Materials, mechanical properties• Speed
– Decentralized use in the various developmentdepartments of a company
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Trends and perspectives II/II
Sources: CMST, http://www.cmst.csiro.au/ undMIT, http://web.mit.edu/tdp/www/directmetaltools.html
Conformal cooling
Rapid Tooling– Improvement of systems– Increase of tool lifetime– Comparability of molding parameters to serial steel
tools– »Conformal cooling«– Graduated build up of tools with changing properties
Rapid Manufacturing– Use of RT-technologies for end product production– Small series production (racing, aerospace,
executive/special products, ...)– »Mass Customization«– Establish beneath/instead of conventional production
methods
Integrated supporting structure forthermal insulation of a tool (3DP)
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Contents
Legende
Rapid Prototyping and Rapid Tooling
Introduction
RP and RT in product development
Economic aspects
Overview about systems and technologies
Examples of application
Future and perspectives
Conclusions
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IPT
Conclusions
Product development– Main goal: reduction of»Time to Market«– Manufacture of models, samples and prototypes using
RP/RT opens cost and time savings– Requirements to models depend on product
development phase
Rapid Prototyping/Rapid Tooling– Layer-by-layer generative build up of parts– Production of a model or a tool– Selection of a technology regarding required
properties, stiffness, materials, batch number, ...– Future developments gain to optimization of
handling, closeness to serial products, production offinal products