Maulana Azad National Institute of Technology Bhopal: Assignment - 1

MAULANA AZAD NATIONAL INSTITUTE OF TECHNOLOGY
BHOPAL
ASSIGNMENT - 1
SUBMITTED TO: SUBMITTED BY:
DR. RAVI KUMAR DWIVEDI SIR SANTOSH CHUVAN

222116307
M.TECH (2ST SEM)
INDUSTRIAL DESIGN
ASSIGNMENT (I)
 Comparison of traditional processes and rapid prototype

processes while explaining merits and demerits of both.
 Traditional Manufacturing Methods
• There are four main families of standard manufacturing

processes: injection molding, machining, forming, and
joining. Similar to 3D printing, each manufacturing process
has advantages and limitations.
 INJECTION MOLDING
• Injection molding is a fabrication process that
consists of softening a plastic material then injecting
it into a mold. Once in the mold, the material cools
and solidifies and another mechanism ejects the
piece from the mold. This mode of fabrication is used
for a wide variety of uses (it is the most common
mode of fabrication for plastic goods) and leaves for
a very high quality surface. However, start up costs
for an injection mold are often very high, and this
mode of fabrication is not ideal for smaller series.
 MACHINING
• Whether referring drilling, milling, or turning,
almost any material can be machined into a
part. In CNC machining, a piece of material
is clamped into the machine, and a
numerically controlled tool removes
material until the part is completed. Similar
to injection molding, material selection is
very broad and can be chosen based on
the desired application.
 FORMING
• There are several types of forming methods for plastics: thermoforming, vacuum
forming, and pressure forming. There are specifics to each type, but each one in
some manner heats a sheet of plastic and drape it over a mold, using air pressure
and male plugs to form the sheet into a shape. Virtually all thermoplastics can be
found as a sheet and used in the forming process.
 PLASTIC JOINING
• The joining of plastics refers to the joining of semi-finished
parts. This includes fastening, adhesive bonding, and welding.
Fastening refers to the incorporating latches, hinges and snap
fits into the design of the part, or using external fasteners such
as bolts and screws. Adhesive bonding means the application
of an adhesive (such as epoxy) to join parts together. Welding
refers to the joining of two parts via the application of heat and
pressure.
 RAPID PROTOTYPING
What is rapid prototyping ?

• Rapid prototyping uses 3D computer-aided design (CAD)
and manufacturing processes to quickly develop 3D parts or
assemblies for research and development and/or product
testing.
 The most common rapid prototyping processes.
 Vat photopolymerization
 Powder bed fusion
 Material extrusion
 Jetting
 Binder jetting
1. Vat photopolymerization.
• A part is created one layer at a time by using light to convert a
photopolymer resin to a solid.
Stereolithography (SLA) :
• It can produce parts with very high dimensional
accuracy and intricate details. However, they are
generally brittle and their mechanical properties may
degrade over time, making the parts typically unsuitable
for functional prototypes. This process is best suited for
rapid prototyping of design geometry and proof of
concept of part interfaces. It is also suitable for details
during the early stages of design and when mechanical
properties are not the primary design focus.
Direct light processing (DLP):

• It is similar to SLA, with the main difference being level of detail and material
properties. Parts produced using DLP do not have the same intricate details as
SLA, but do have similar dimensional accuracy and part strength considered
equal to or greater than traditional injection molded parts
 Powder bed fusion.
• Powder bed fusion (PBF) technologies produce a solid part using

a thermal source that induces fusion, via sintering or melting,
between the particles of a plastic or metal powder, one layer at a
time. The main variations in PBF processes are determined by
the differing energy sources (e.g. lasers or electron beams) and
powders (plastics or metals).
1. Selective laser sintering (SLS)

• It uses thermoplastic polymer materials that come in granular form. Since SLS
parts are printed using many layers, small variations can occur between parts.
SLS may therefore be less effective for prototypes with intricate details or small
tolerances. A smooth surface finish is also possible to achieve when post-
processing is used.
2.Selective laser melting (SLM) and
direct metal laser sintering (DMLS)
• It can be used for a wide variety of metal materials and typically
require postprocessing for surface finish. These processes are
therefore best suited for rapid prototyping when material properties
are a design priority. They can be cost-effective if part finish is not a
concern.
 Material jetting
• It is considered one of the most accurate 3D printing technologies and can be

used with a wide array of materials in varying colors and finishes. However,
material properties are not suited for functional prototypes. Material jetting is best
used for rapid prototyping when part geometry or fit is a design priority and part
strength is not required.
 Binder jetting
• Parts made with binder jetting have a high finish and form,
though they are brittle. Binder jetting is best suited for rapid
prototyping when overall fit or part geometry are a design priority
and there is no concern about material properties, such as proof
of concept or marketing prototypes.
 Material extrusion
Material extrusion is an additive manufacturing (AM) technique that deposits a

continuous filament of composite or thermoplastic material to build 3D parts layer
by layer. The filament is fed from a spool through a heated extruding nozzle,
which heats the material and deposits it onto a build platform.
 Advantages of rapid prototyping
•Earlier 3D visualization and testing

•More design iterations at a lower cost
•Cost-effective tool for product design and research and development
 Disadvantages of rapid prototyping
•Overuse may not have a positive impact on saving costs or time

•Not beneficial to all stages of the prototyping process
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MAULANA AZAD NATIONAL INSTITUTE OF TECHNOLOGY

SUBMITTED TO: SUBMITTED BY:

DR. RAVI KUMAR DWIVEDI SIR SANTOSH CHUVAN

 Comparison of traditional processes and rapid prototype

• There are four main families of standard manufacturing

What is rapid prototyping ?

Direct light processing (DLP):

• Powder bed fusion (PBF) technologies produce a solid part using

1. Selective laser sintering (SLS)

• It is considered one of the most accurate 3D printing technologies and can be

Material extrusion is an additive manufacturing (AM) technique that deposits a

•Earlier 3D visualization and testing

 Disadvantages of rapid prototyping

•Overuse may not have a positive impact on saving costs or time

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