1 ……………………………………………….

……………Rapid prototyping:
Stereolithography
INTRODUCTION
Introduction new products at ever increasing rates is crucial for remaining successful
life in a competitive global economy decreasing Product development cycle times &
increasing product complexity require new ways to realize innovating ideas. In response to
these challenges, industry & academia have invented a spectrum of technologies that help to
development new products & to broaden the number of product alternatives. Rapid
prototyping is one of the techniques.
The term rapid prototyping refers to class of technologies that can automatically
construct physical models from computer aided design (CAD) data. These “three
dimensional printers” allow designers to quickly create tangible prototypes of their designs,
rather than just two-dimensional pictures. Such models have numerous uses. They make
excellent visual aids for commenting ideas with coworkers or customers. In addition
prototypes can be used for design testing for example an aerospace engineer might mount a
modal air foil in a wind tunnel to measure lift & drag forces designers have always utilized
prototypes, of rapid prototyping technique allows them to be made faster & less
expensively.

REPID PROTOTYPING TECHNIQUES

Rapid prototyping techniques is the name given to the class of manufacturing
processes that allow objects to be constructed by building up a structure from individual
layers. The layered construction method allows complex structure to be built that would be
prohibitive or impractical using more traditional methods, and in a fraction of time. At
present time, there many different processes that fall under this umbrella term, using a
variety of materials and methods. What they have in common is that they may each be given
as input a three dimensional model (described by a computer file), along with a set of
perimeters particular to the process. The computer model is automatically sliced into layers
by calculating its intersection with a set of parallel planes, spaced according to the
resolution of the process. Each of the processes then constructs the object by building up
reproductions of these layers in physical material.
Most commercially available rapid prototyping machines use one of the six
techniques.
• Laminated Objected Manufacturing.
• Fused Deposition Modeling
• Sterolithography
• Solid Ground Curing.
• Selective Laser Sintering
• Three Dimensional Printing
Rapid prototyping is widely used in automotive aerospace, medical and consumer
products. Although the possible applications are virtually limitless, nearly all full into one of
the following categories. Prototyping, rapid tooling or rapid manufacturing.

STEREOLITHOGRAPHY
Stereolithoraphy is one of the several available methods of predicting rapid
prototype models. The process allows complex shapes to be reproduction in polymer resin,
going from computer data to finished product within a period of 24 hours. Rapid
prototyping techniques are increasingly being used by industry to produce models in a
fraction of time required for more conventional mfg. Methods. Stereolithogphy is widely
used through all manufacturing industries to accelerate the design product development
process by addressing three application areas: models patterns and masters.
The main component of a Stereo lithography system a vat containing liquid
photopolymer, galvanometer controlled mirrors, directing a UV laser onto the surface of
2 ……………………………………………….……………Rapid prototyping:
Stereolithography
liquid and just below the surface, vertical elevator tray. The Stereo lithography process is
basically comprised of 4 major steps.
I) CAD Process
I) Part Preparation
II) Setup and Build.
III) Post Processing.
1. CAD Process
The CAD process involves the utilization of a CAD system to structure object/ part
date for use on the Stereolithography apparatus (SLA). The process being with a design
created on a solid modeling CAD system. Pro/Engineer and Auto CAD 13 with 3D
modeling extension are 2 examples available 3D modeling software packages.
2. Part Preparation
This process is performed utilizing the SLA manufactures proprietary software.
Typically, 3 part orientation tasks are performed.
These include : placing the parts in positive space, orienting the parts in such a way
as to minimize support structure and positioning the parts to optimize the total number of
parts to be made during the build process. At this stage of the part preparation process, if
required, the parts can easily be scaled up or down in size. One orientated, the parts are then
supported. Support structure is required to hold a part in place on the elevator tray and
support any overhanging surfaces that are greater then 1/8” at any angle less than fifty
degree from horizontal. Support structures are basically thin vertical webs.
These parameters which are defined on a spread sheet include part build layer
thickness (0.006 in), resin shrinkage compensation for increased part dimensional accuracy,
resin specific parameters, setting time between layers and wiper arm start point and sweep
pattern.
3. Setup & build
The third step of the Stereolithography process involves the initialization & setup to
build parts on the SLA. Prior to initializing the build process, the laser is warmed up for 15
min. The time required allows the laser to stabilize and reaches maximum output capacity.
During the warm up period three tasks are performed: transfer of slices and operational data
files from slice workstation to SLA control computer, lowering of platform into vat and
resin level adjustment. The process of SLA software is now activated by the operator, which
begins building the part by moving a focused laser beam across the surface of the vat of
resin. The laser draws the first support cross-section, which adheres to the platform.
Typically .3 inches of base support structure of built up before initiating the part build itself
& whatever additional support are needed for over hanging surfaces.
4. Post processing
The final step post processing involves cleaning UV curing & final finishing of the
part. First, the part is raised out of the vat & as much liquid resin as possible is allowed to
drain off the part.
The part & the platform are then removed from the process chamber & the remaining
excess liquid resin is removed by rinsing in a solvent with the aid of an ultrasonic cleaner.
The part is then removed from the platform & support structure is removed from the part.
Ultraviolet light to solidify any remaining trapped liquid & increase strength of part.
Post curing is required, since a part is only about to go percent cured by SLA’S ultraviolet
laser when it is built. The final cured part can be finished in a number of ways. Finishing
techniques such as sanding, sand blasting, painting, polished can be applied. The
steriolithoraphy lab is equipped with majority of items required for finishing which include
a sand blaster.
3 ……………………………………………….……………Rapid prototyping:
Stereolithography
BENEFITS OF STEREOLITHOGRAPHY
Wherever there is a product to be designed, manufactured & sold, there is an
application for Stereolithogrphy. Almost every type of product design, from jet engines to
perfume bottles, requires a prototype or mode. Stereolithography provides a fast efficient
solution. Even collages & universities are finding Stereolithography of great benefit in
teaching & research programs. The early exchange of ideas among those work concurrently
to create & market innovative products is a key to success in today’s global marketplace.
Sterolithography is an enabling technology to concurrent engineering that allows products
design, engineering, R & D, manufacturing, marketing purchasing operations and corporate
management to work as a more cohesive team to achieve batter design, efficiency,
productivity, & quality. And these benefits are just the beginning speed & cost savings can
be considerable when Sterelithography is compared to traditional prototyping process.
Because concept models can be produced within hours, more design iteration can occur
without impacting time to market. Design problems can be solved before production,
avoiding costly redesign & retooling. And by eliminating costly manual procedures &
programming of machine tools, the development cycle is shortened. As a result, product
quality assurance levels rise significantly providing further competitive advantage in
reducing warranty cost.

LIMITATIONS OF STEREOLITHOGRAPHY
The resins used in stereolithography are not capable of bearing the types of loads
endured the production parts, so structural testing is generally not possible.

APPLICATIONS OF STEREOLITHOGRAPHY
Design Review
Rapid prototypes allow users to quickly evaluate a design for potential problems.
Simple errors which can be hard to pick up in a standard two dimensional CAD drawing are
obvious once the designer can hold a real part or tool in his hand.
Design Verification
Users can actually put actual size prototypes in to the parts intended spot to test for
accurate fit. Previously expensive molds had to be tooled before a prototype could be tested
within a structure. If the prototype did not fit, because of an error in the geometry of the
part, the tools have would have to be changed.
Patterns For Moldes
Stereolithography is not just for making prototypes. Many companies are now using
Stereolithoraphy to make injection molds for their plastic & rubber parts. Stereolithography
molds can be cast in hours pr days rather than weeks, and they cost a fraction of the price of
standard mold.
Presentations
Companies can now do marketing presentations with real three-dimensional models.
Customers benefit by seeing and touching model of the part or tool they went to purchase,
rather than an abstract 2 dimensional wire drawing or diagram.
Short Run Production
Small volume products which previously would not be considered by manufactures
due to tooling cost, can now be produced and shipped in days. This allows manufactures
more flexibility to meet special customer requirements.

CASE STUDY: APS IS COMPANY (U.S.A.)

4 ……………………………………………….……………Rapid prototyping:
Stereolithography
APS IS a company which produces stereolithography parts by consulting with
customer. It offers a state of art technology in stereolithography. APS had delivered
prototype parts in less than 24 hours.

Situation:
Marketing U.S.A. specializes in helping individuals and companies develop and bring
new product to market. On May 19, 1998, the Sheboygan, Wisconsin based company
decided to manufacture and market product idea it had patented, the Deco-hanger. This
special tool consists of special plastic chips and an extendable pole with a special end cap.
The Deco-hanger is designed to conveniently hang holiday light strings or garlands on
gutters.
to make in market in time for the Christmas in 1998 season ,
the company needed a finished product prototype on May, 30.

Assignment:
APS was asked to use 2D drawing made by Sheboygan into a product prototype in
time for May, 30.Producing plastic chip hangers required working with several materials to
find one with right elasticity and colour qualities.
APS worked with three plastics before finding the materials with right qualities.APS
used software to create SL mould based on 3D CAD models to produce pole end with
special knobs for hanging and removing clips. A SL prototype and the pole end cap were
later used to cast a mould in high temperature
composite material.
by using stereolithography technique, APS produced the final product prototype in
time to allow Marketing U.S.A. to show it at the May, 30 trade just 9 working days after
starting the project.

RAPID PROTOTYPING IN INDIA

With its strong engineering base, liberalized economy and rising consumerism, India
is expected to rapidly increase its industrial output in terms of both engineering and
consumer products for domestic as well as export market. However, a majority of the
products are direct descendents of similar products elsewhere, product innovation at a
grassroots level is yet to take off in a major way. Moreover, the appreciation of time as a
competitive factor is only just beginning to emerge. Even if the prototypes are manufactured
in a day instead of several weeks, other bureaucratic hurdles delaying the project would
negate the competitive advantage of rapid prototyping. It therefore appears that in short
term, the cost of rapid prototypes would have to be comparable to those producted by
conventional routes. Thus of rapid prototyping technology would find the greatest use in
fabricating small and highly intricate components.
The major and immediate attraction of rapid prototyping would be in producing the
patterns, moulds and dies for metal casting, plstic injection molding and sheet metal
forming industries.

CASE STUDY:
In 1998 at beech candy hospital (Mumbai)
A thirty five year old person was having tumor in brain. Doctor removed out X-ray
film but he could not get the idea about carrying surgery. He called mechanical engineer
who was knowing of rapid prototyping technique.
Doctor asked that person to prepare prototypes of brain with tumor. That person did
so and he placed 2 prototypes in front of doctors .By comparing the prototypes, doctor
could get the idea & surgery was carried out successfully.
5 ……………………………………………….……………Rapid prototyping:
Stereolithography

CONCLUSION:
Rapid prototyping is an enabling technology for concurrent engineering. Its goal is
to reduce product development and manufacturing costs and lead times, thereby increasing
competitiveness. Impressive steps towards the goal have been made. However, the field of
of rapid prototyping technique
is still new, with much efforts to be expended on improving the speed accuracy, and
reliability of of rapid prototyping technique systems and widen the range of material for
prototype construction. Another area of improvement will be costing, as most of rapid
prototyping systems are currently expensive to be affordable by any but the large firms.
Although of rapid prototyping technology will continue to be available to all companies via
bureaux, which often in partnership with traditional model markers can provide a
comprehensive service from design through to short run production, the future is likely to
see more user-owned of rapid prototyping technique machines as their costs are reduced.
There will also be two different types of of rapid prototyping technique systems for two
distinct markets the design office “3D-Plotter” for rapidly generating parts for design
verification and workshop/ model making shop machine for producing accurate functional
parts.

BIBLIOGRAPHY
TEXTBOOKS:
Rapid Prototyping and tooling
By, K.P.Karunakaran and V.P.Bapat
RP cell, IDC, IIT Bombay.
Manufacturing Engineering & Technology
By Kalpakjian , Addision-wesley Publication
3rd Edition
A Comparison of Rapid Prototyping Technologies
By D.T.Pharm, R.S.gault
International Journal of Machine tools & Manufacture
“Saving Time, Money & Resources” Agricultural Engineering
Page no.11-15 Nov 1991
“Computer Aided Journal”
Nov.1996, March 1998..Penton Publication.
WEBSITES:
www.stereolithography.com
www.sglinc.com
www.expertpages.com/news/stereo.html
www.thomasregional.com
www.okino.com