SRINIVAS.M.K 1MS11MCM13 3RD SEM,M.TECH RAPID PROTOTYPING M.S.R.I.

RAPID PROTOTYPING PROCESSES ARE:

1.STEREOLITHOGRAPHY APPARATUS(SLA) 2.SELECTIVE LASER SINTERING(SLS) 3.LAMINATED OBJECT MANUFACTURING(LOM) 4.FUSED DEPOSITION MODELING(FDM) 5.SOLID GROUND CURING(SGC) 6.THREE-DIMENSIONAL PRINTING(3DP)

Advantages
1.The raw material can be re-used. 2.Continuous process. 3.No tooling is required. 4.Capable of high detail and thin walls. 5.Achieving accuracy in industries.

6. Good surface finish. 7. Market shares and industry presence. 8. Most accurate Rapid Prototyping Procedure at the moment. 9. Can produce components of high complexity. 10.Build time is less per layer thickness.
Engine manifold using the SLA process.

1.Initial investment is high. 2.Requires post-curing. 3.Some warpage, shrinkage and curl due to phase change. 4. Support structures always needed,removal of support structures can be difficult. 5.Prototype has no load capacity.

6.Skilled labours is required.

Advantages 1.The main advantage is that the fabricated prototypes are porous (typically 60% of the density of molded parts), thus impairing their strength and surface finish.

2.Variety of materials.
3.No post curing required. 4.Fast build times.

5.Limited use of support structures. 6.Mechanical properties of Nylon & Polycarbonate parts. 7.High mechanical and thermal load capacity of the parts. 8.No post-cross-linking and only little rework required. 9.Models can be used immediately. 10.Material not sintered can be re-used in follow-up processes.

1.Surface finish: The surface of an SLS part is powdery, like the base material whose particles are fused together without complete Melting.The smoother surface of an SLA part typically wins over SLS. 2.Dimensional accuracy:SLA is more accurate immediately after completion of the model, but SLS is prone to residual stresses that are caused by long term curing and environmental stresses. Both SLS and SLA suiler from inaccuracy, but SLS is less predictable because of the variety of materials and process parameters. 3.Accuracy: the accuracy of a rapid prototype is dependent on many factors. Upon completion of the prototype the SLA provides greater accuracy than SLS. 4.Heating up and cooling down procedures are time-consuming. 5.Performing the sintering process is required in a nitrogen atmosphere.

Advantages 1.No "heating time" is required. 2.No supports needed.

3.Non-toxic materials.
4.The laser only has to cut the part outline and hatching, not all the internal area. 5.No chemical changes, and minimal heating, so the shrinkage is minimum,and stress induced deformation is very small.

6.Larger working area than most RP technologies. 7.Cheap materials. 8.The system is inexpensive to maintain. 9.A large variety of materials can be used. 10.Machines are well suited to desktop operation.

1.Removal of the tiles can be difficult because the laser cuts through the layers, not between them.

2.Cross hatching is used to "burn-out" and weaken materials.

3.Delicate parts can be damaged when removing tiles.

4.Machinability is limited because of delamination.

5.Enclosed volumes will trap the support material.

6.However cheap the material may be, it generates a lot of waste compared to other methods.
7.Ventilation is required for fumes when burning.

Advantages 1.Relatively simple process technology. 2.No loss of materials. 3.No specific requirements to the environment of the machine. 4. Fast small part production.

5. Usage of water soluble materials allow support structures to be easily removable.

6.Good for parts with thin walls.

7. Numerous Material Available :

ABS

Casting waxes
Nylon like polymers Water soluble materials

8.Good layer bonding with ABS materials.

1.Slow production rates for thick sectioned parts. 2.Poor surface finishing. 3.Precise slots, ribs, domes and thin wall thickness cannot be formed. 4.Extrusion width limits geometry to be formed. 5.Process is only suitable for smaller parts. 6.Weak Z-axis. 7.Support design / integration / removal is difficult.

Advantages 1.No need for time consuming post-curing. 2.Part complexity does not effect speed of the process. 3.Models with moving parts can be produced because of the firm holding of work in the process. 4.Weights may be inserted at any time to alter the centre of gravity.

5.Elimination of postcuring reduces internal stresses, and warping.

6.Many parts can be run at the same time.

7.Supports are not required.

8.Layers can be milled off if they are found to be in error part complexity does not effect speed, however volume does.

1.Overexposure of the polymer may increase the viscosity, and make it unusable, thus greatly increasing the volume of expensive polymers used. 2.The resins require that light sealed chambers and toxic material handling procedures be used. 3. The machine is very large. 4. Machining is noisy. 5. Maintenance is high, requires supervision. 6.Very few materials available. 7.Removal of wax after production is required.

Advantages
1.Increase Innovation. 2.Speed Time To Market. 3.Reduce Development Costs. 4.Print items in remote locations. 5.plastic used is strong.

1. Current 3D printing materials for investment casting tend to yield sporadically rough surfaces.

2. Sometimes encourages informal design methods which may cause more problems to fix.
3. It may not be suitable for large sized applications.

4. The user may have very high expectations about the protypes performance and it might fail in the exact replication of the real product or systems.
5. 3-D printers are still expensive. 6. Although,3-D printers have the potential of creating many jobs and opportunities, they might also put certain jobs at risk (for example, you can make your toys at home so toy stores and toy makers might go out of business).