Manufacturing Engineering and Technology By: Quentin Allen Angelo Juniel

Rapid Prototyping and Processes and Operations Technologies associated with rapid prototyping. Materials used with rapid prototyping. Revolutionary practice of applying rapid-prototyping techniques to the production of tooling that can be used in other manufacturing processes.

Key Terms ACES Electron-beam melting Photopolymer Additive processes Free-form fabrication Polyjet Ballistic-particle Fused-deposition modeling Prototype manufacturing Keltool Rapid tooling Desktop machines Laminated-object RTV molding/urethane Direct AIM manufacturing casting Direct manufacturing Multijet modeling Selective laser sintering BIBLIOGRAPHY Bibliography 549 Solid-ground curing Sprayed metal tooling Stereolithography Subtractive processes Three-dimensional printing Virtual prototyping

Developing a New Product In a manufacturing process, prototyping is used as an example before the finished product. There are 3 main reasons we use prototyping. Capital cost Design evaluation Troubleshooting

Rapid Prototyping Rapid prototyping is used to speed up the development process, so a final product can be introduced into the market quicker. Rapid prototyping or RP is also known as desktop manufacturing, digital manufacturing and solid free form fabrication.

Rapid Prototyping example 3d printed gear shift prototype Ford Motor company saves more than $500,000 annually and months of lead time through 3d printing rapid prototyping process.

Major groups of Rapid prototyping There are three types of prototyping processes. Subtractive Process- involves material removal from a work piece that is larger than the final part. Additive Process – build up a part by adding material incrementally to produce the part. Virtual Process – uses advance computer based visualization technologies.

Subtractive Process Subtractive Process- involves material removal from a work piece that is larger than the final part.

Additive Process Additive process – build up a part by adding material incrementally to produce the part.

Virtual Process Virtual Process – uses advance computer based visualization technologies

Subtractive Process The Subtractive Process can take weeks or months to produce a product. Part Complexity or size Machine operator kill Machine availability There are several computer-based technologies the speed up process. Computer Based Drafting Packages – which can product 3D representations of parts. Interpretation software – which can translate the CAD file into useable manufacturing software. Manufacturing Software – which is capable of planning the operations required to produce a desire shape. Computer-numerical-control machinery – with the capabilities nessacy to product produce.

Additive Process The Additive process only takes a few minutes to an hour to produce a part. Due to setup and finishing operations that are very labor high intensive. Sanding Painting Additive operations require CAD software. Here are a few additive manufacturing technologies. Fused-deposition modeling(FDM) a gantry robot, that moves in 2 directions on a table. Stereo lithography(STL) principles of curing a liquid photopolymer into a specific shape. Multijet/Polymer Modeling(MPM) User UV bulbs, alongside jets they immediately cure each layer.

Additive manufacturing technologies MIT lists additive manufacturing as one of the top ten breakthrough technologies. GE chooses electric beam melting, to create its jet engine prototypes. These technologies have been proven to reduce production cost, faster development, and reserves unused materials.

Other additive technologies Sensor laser sintering- allows materials to be sintered, using a laser beam and CAD software programs. The materials are usually non metallic and metallic powders. Electric beam melting – is used when a piece is produced in a vacuum tube, with electron beam scanning. Three Dimensional Printing – uses a print head process to create inorganic products. Its commonly related to printing a binder onto powder. Laminated object manufacturing – consists of using control software and vinyl cutters to develop a prototype. LOM is similar to creating sheets of paper with a CNC machine but more economically beneficial.