Dr. HABEEB HATTAB HABEEB Dr. HABEEB HATTAB HABEEB Office: BN-Block, Level-3, Room Ext. No.: 7292 UNITEN University TENAGA Nasional Lecturer: Habeeb Al-Ani Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

U niversity TENAGA National College Of Engineering Mechanical Department Academic Year – Lecture Note University TENAGA Nasional Lecturer: Habeeb Al-Ani UNITEN Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

CAM University TENAGA Nasional Lecturer: Habeeb Al-Ani Computer Aided Manufacturing UNITEN Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Rapid Prototyping(RP) Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Manufacturing? 1. Removal (subtractive) 2. Near Net Shape or Net Shape 3. Additive Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

-Easy planning for 3D -Material Variety - Fast turn around -Accuracy: Layer thickness Rapid prototyping 1 Step 2 3

Rapid Prototyping Also called – Layered Manufacturing (LM) –Desktop Manufacturing (DM) –Solid Freeform Fabrication (SFF) Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Layered Manufacturing ?

Parts Made by RP Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

1. Build complex 3D geometries 2. Automatic process planning, based on CAD model 3. Generic fabrication machine, i.e., do not require part-specific fixturing or tooling Benefits of RP Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

4. Require minimal or no human intervention to operate Benefits of RP……. Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Application Capabilities for RP 1.One-of-a-kind item or small number parts (normally up to 3000 units) 2. Shape of object in computer form 3.Complex Shape and Complex Microstructures Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Fused Deposition Modeling (FDM) Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

(FDM) -Most widely used rapid prototyping technology -Occupied around 25% of all RP systems in the world Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Schematic illustration of the fused deposition-modeling process. FDM Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Materials for FDM Several materials are available 1. (ABS) Acrylon Butadiene Styrene offers good strength 2. investment casting wax 3. polycarbonate material Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Characteristics for FDM features 1. Office-friendly and quiet – No toxic fume and chemicals – no waste 2. Fairly fast – For small parts on the order of a few cubic inches – or those that have tall, thin form-factors Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Characteristics for FDM features….. 3. No part clean-up needed 4. Materials used are very cost effective, typical parts cost under US$20 5. The finish of parts improved over the years – but not quite good – Accuracy is relatively low and is difficult to build parts with complicated details Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Applications for FDM 1. Conceptual modeling 2. Fit, form and functional test 3. Pattern for investment casting 4. Medical applications Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Three-dimensional Printing (3DP)/(3D Printing) Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

3DP Process Each layer begins with a thin distribution of powder spread over the surface of a powder bed Using a technology similar to ink-jet printing, a binder material selectively joins particles where the object is to be formed Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

A piston that supports the powder bed and the part-in-progress lowers so that the next powder layer can be spread and selectively joined This layer-by-layer process repeats until the part is completed Following a heat treatment, unbound powder is removed, leaving the fabricated part 3DP Process……… Lecturer: Dr. HABEEB ALANI University TENAGA Nasional

Spread powderPrint layerPiston movement Operation Sequence of 3DPrinter Process Schematic illustration of the three-dimensional-printing process.

Lecturer: Dr. HABEEB ALANI University TENAGA Nasional