1. A SEMINAR ON 1

2. CONTENTS Prototyping Rapid prototyping process Stereo lithography  Machine  Process  Material used Benefits Application Problems with RP Conclusion Reference

3. PROTOTYPING Subtractive (conventional process)  Milling  Grinding  Turning Compressive Additive  Photopolymer  Thermoplastic  Adhesives 3

4. Why Rapid Prototyping Reduce product development time and cost Get products to market sooner Enhance communications between marketing, engineering, manufacturing, and purchasing Present physical model at critical design reviews Generate precise production tooling 4

5. Rapid Prototype Process You create a 3-D model of your object in a CAD program Computer Aided Design (CAD) Rapid Prototyping Device 3-D Object 5

6. BASIC PROCESS Create CAD model of the design Conversion to STL format Slice the STL file Layer by layer construction Cleaning and finishing 6

7. Slices 7

8. Conversion of a solid model of an object into layers (only one layer is shown) Software chops your CAD model up into thin layers -- typically five to 10 layers/millimeter 8

9. SLA Interface Stereolithograpy was first commercial Solid Freeform Manufacturing process, released in 80’s by 3-D Systems 3-D Systems developed interface between CAD systems and their machine STL files (*.stl) allow CAD systems to interface with 3-D system machines Many CAD programs now can export the *.stl file for easy conversion from CAD to part 9

10. A typical Stereo lithography apparatus. 10

11. PARTS OF A SLA MACHINE Tank filled with several gallons of liquid photopolymer. The photopolymer is a clear, liquid plastic. A perforated platform immersed in the tank. The platform can move up and down in the tank as the printing process proceeds. An ultraviolet laser A computer that drives the laser and the platform 11

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13. SLA PLATFORM 13

14. INSIDE OF SLA MACHINE 14

15. Polymer solidifies when struck by the laser’s intense UV light Elevator lowers hardened cross section below liquid surface Laser prints the next cross section directly on top of previous After entire 3-d part is formed it is post- cured (UV light) STEREO LITHOGRAPHY PROCESS 15

16. Stereolithography: (1) at the start of the process, in which the initial layer is added to the platform; and (2) after several layers have been added so that the part geometry gradually takes form 16

17. SLA MODEL BUILDS…. 17

18. SLA MACHINE-OBJECT CURING PART 18

19. Applications of SLA Technology Aesthetic & conceptual models Parts requiring detail & accuracy Master patterns for castings 19

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22. Benefits of SLA Crisp, highly- detailed pieces Speed of delivery (usually 2-3 days) Tolerances within.005"/inch Save Money Save Time Test Product Catch Errors Improve Design Rapid Manufacturing 22

23. Problems with Rapid Prototyping Part accuracy: Staircase appearance for a sloping part surface due to layering Shrinkage and distortion of RP parts Limited variety of materials in RP Mechanical performance of the fabricated parts is limited by the materials that is used in the RP process 23

24. Conclusions Stereolithography is fast and effective. Stereolithography can be applied to almost every industry, including oil refining, petrochemical, power and marine. Stereolithography saves time, money, allows speed delivery, and improve designs. 24

25. A MODEL.. 25

26. Reference Base Paper: Stereolithography: Speeding Time to Market, Diana Kalisz,IEEE “ Advanced High Temperature Resins for Stereo Lithography” from proceedings of 7 th International conference on Rapid Prototyping, University of Dayton, San Francisco. http://en.wikipedia.org/wiki/Stereolithography 26

27. THANK YOU 27

28. QUERIES ?? 28