RPRE

RAPID PROTOTYPING
Rapid Prototyping is the automated fabrication technologies of seamless and rapidly

creating accurate representative physical models of mechanical parts directly from 3-
Dimensional Computer Aided Design (CAD) data without the use of tooling and with minimal
human intervention.
Rapid Prototyping (RP) uses state of the art laser technology, positioning systems,
materials and computer technologies in the various processes. There are many RP processes that
are widely used, each one using different methods and materials to produce the final part.
Benefits or advantages of Rapid Prototyping:

1. Reduces design phase cycle time and costs.
2. Reduces the potential for expensive design errors.
3. Reduces tooling costs on short-run parts.
4. Impresses the customer with quick response.
5. Reduces time to production and market.
Basic Process steps in Rapid Prototyping:

1. Create CAD model of the design.
2. Convert the CAD model to STL format.
3. Slice the STL file into thin cross-sectional layers.
4. Layer by layer construction.
5. Clean and finish the model.
Rapid Prototyping Techniques:

1. Stereo lithography.
2. Laminated object manufacturing
3. Selective Laser Sintering
4. Fused Deposition Modeling
5. Solid ground curing
6. 3-D inkjet printing
Drawbacks or Limitations of Rapid Prototyping:

1. The Rapid Prototyping produced part or tool is built to near net shape.
2. Additional machining, polishing or other processes may be needed.
3. Materials should have excellent machining properties.
4. There may be quantity and use limitations.
Rapid Prototyping Materials:

1. Metals - Steel alloys, Aluminium, Titanium, super alloys.
2. Non-Metals - Plastics, ceramics, composites, blended materials in a single part.
1
Rapid Prototyping Applications:
1. A design verification and optimization tool to qualify the form / fit / function of
individual parts and assemblies.
2. Concept visualization tools to verify design details and gain internal design acceptance
and justification.
3. A communication tools for internal design reviews, for design reviews with the customer
and for dry fit installation checks.
4. As a three dimensional fixture for bending or routing tubing or cables.
5. As an inspection fixture for parts with complex or compound surfaces and fixtures.
6. As a model to test airflow, ducting, diverters and channels.
7. To create light duty plastic parts for light duty use, such as ducting.
8. As a mold for gaskets, keypads, etc.
9. Most Rapid Prototyping parts may be machined, drilled and tapped, sanded, painted,
baked, plated, bonded and coated with EMI protection.
Feature development in Rapid Prototyping:

1. The first important development is accuracy and surface finish (~0.08mm).
2. Another important development is increased size capacity.
3. Increase in the speed.
REVERSE ENGINEERING
It is a process that is used to create 3D CAD models directly from physical parts with
little or no additional design documentation. It is simply the act of figuring out the real parts
using software that you have.
Where Reverse Engineering Useful:

 In many cases it is extremely difficult to clearly define physical part geometry using
traditional measurement techniques.
 Reverse Engineering quickly and accurately bridges the gap between poorly or
undocumented tooling and fully modifiable 3D CAD models useful for modern
manufacturing methods.
Reverse Engineering Process Stages:

1. Sample parts or objects provided are digitized.
2. The data is refined and used as a foundation for creating one of the various 3D file types
available. (STL, STEP, IGES, etc.).
3. Prototype models are made for design confirmation and market evaluation purposes.
3D DIGITIZING
Product scanning also known as digitizing or 3D digitizing is a process that uses light to
capture the shape of three-dimensional objects and recreate them in a virtual workspace. The
data is collected as points and the resultant file is called a point cloud.
2
3D digitizing process steps:
1. Light is projected onto the object.
2. The object reflects the light, which is then collected by a digital sensor.
3. Using algebraic equations, the 3D coordinates of the surface point are calculated.
4. The point’s coordinate location is stored as part of a point cloud representing the physical
part.
5. Millions of points are collected this way until the entire surface of the part or object has
been digitized.
6. The digital data (point cloud) is used for reverse engineering, Rapid Prototyping and
product inspection.
Use of 3D digitizing:
It captures high-density geometry, compound surface curvature, and draft that are
difficult to measure using traditional measurement techniques.
Materials for digitizing:

1. Stone 2. Ceramic 3. Glass 4. Metal 5. Wood
6. Bone 7. Plastic 8. Rubber 9. Wax 10. Clay
Uses of Point Cloud:

 For making 3D model using Reverse Engineering.
 Making Prototype from the 3D model by converting it to STL format.
 Product inspection purposes (Comparing RP model with an existing CAD model and
used to create a color error map).
Limitations of 3D Digitizer:
1. In many cases castings can be made of internal passages that can be digitized separately
and added to the external geometry.
COORDINATE MEASURING MACHINE

Coordinate Measuring Machines are mechanical systems designed to move a measuring
probe to determine coordinates of points on a workpiece surface.
Main Components of CMM:
1. Measuring Probe
2. Computing Unit
3. Measuring Software
4. Machine itself.
Specification for CMM:

1. Measuring lengths along x, y & z-axes.
2. Resolution
3. Workpiece weight and size.
3
Applications of CMM:
1. Dimensional measurement.
2. Profile measurement
3. Angularity or orientation measurement
4. Depth mapping
5. Digitizing or imaging
6. Shaft measurement
Features common to CMM:

1. Crash protection
2. Offline programming
3. Reverse Engineering of part
4. Shop floor suitability
5. Software along with machine
6. Temperature compensation.
PRODUCT INSPECTION
Digitizing / Scanning data that represents the physical production part geometry is
compared to the original design is called product inspection
Product Inspection Process Steps:

1. The product or component is digitized.
2. The data is refined and registered to the CAD model.
3. The distance from each data point to the surface of the model is measured in a direction
normal to the CAD surface. Based on the calculated distance, the point is assigned a
color.
4. Color plots showing the part in various positions are created, and a custom format report
is prepared.
5. The report is delivered both electronically in PDF format and in hardcopy.
Application areas of Product Inspection:

 Consumer electronics.
 Recreational
 Automotive
 Aerospace
 Defense
 Medical application
Advantages of Product Inspection:

1. Comparison of the physical data with the design model results in a 3-dimensional
deviation map that has excellent color separation and is high resolution.
2. Our color error maps literally provide thousand dimensions at a glance.

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RAPID PROTOTYPING

Rapid Prototyping is the automated fabrication technologies of seamless and rapidly

Benefits or advantages of Rapid Prototyping:

Basic Process steps in Rapid Prototyping:

Rapid Prototyping Techniques:

Drawbacks or Limitations of Rapid Prototyping:

Rapid Prototyping Materials:

Feature development in Rapid Prototyping:

Where Reverse Engineering Useful:

Reverse Engineering Process Stages:

Materials for digitizing:

Uses of Point Cloud:

COORDINATE MEASURING MACHINE

Specification for CMM:

Features common to CMM:

Product Inspection Process Steps:

Application areas of Product Inspection:

Advantages of Product Inspection:

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