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CHAPTER 19

Rapid-Prototyping Operations

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Rapid Prototyping Examples

Figure 19.1 (a) Examples of parts madeby rapid prototyping processes. (b)Stereolithography model of cellular

phone.

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Stereo-lithography

Figure 19.2 Thecomputationalsteps in

producing astereolithographyfile. (a) Three-dimensionaldescription of

part. (b) The partis divided into

slices (only one in10 is shown). (c)Support materialis planned. (d) Aset of tooldirections isdetermined tomanufacture eachslice. Shown isthe extruder pathat section A-Afrom (c), for afused-deposition-

modelingoperation.

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Fused-Deposition-Modeling

Figure 19.3 (a) Schematic illustration of the fused-deposition-modeling process. (b) The FDM 5000, afused-deposition-modeling-machine. Source:Courtesy of Stratysis, Inc.

(a) (b)

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Common Support Structures

Figure 19.4 (a) A part with a protruding section which requires support material. (b) Common supportstructures used in rapid-prototyping machines. Source: P.F. Jacobs,Rapid Prototyping &

Manufacturing: Fundamentals of Stereolithography. Society of Manufacturing Engineers, 1992.

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Stereolithography

Figure 19.5 Schematicillustration of thestereolithography

process. Source: UltraViolet Products, Inc.

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Example of Stereolithography

Figure 19.6 A two-button computermouse.

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Selective Laser Sintering

Figure 19.7 Schematic illustration of the selective laser sintering process. Source: After C.Deckard and P.F. McClure.

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Solid-Base Curing

Figure 19.8 Schematic illustration of the solid-base-curing process. Source: After M. Burns,Automated Fabrication, Prentice Hall, 1993.

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Three-Dimensional Printing

Figure 19.9Schematicillustration ofthe three-

dimensional-printingprocess.Source: AfterE. Sachs andM. Cima.

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Laminated-Object Manufacturing

Figure 19.10 (a) Schematic illustration of the laminated-object-manufacturing process. Source:Helysis, Inc. (b) Crankshaft-part example made by LOM. Source: After L. Wood.

(a) (b)

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Sand Casting Using Rapid-Prototyped Patterns

Figure 19.12 Manufacturing steps in sand casting that uses rapid-prototypedpatterns. Source: 3D Systems, Inc.

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Sand Casting (continued)

Figure 19.12

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Rapid Tooling

Figure 19.13 Rapidtooling for a rear-wiper-motor cover