Rapid Product Development

(MM4RPD)
Lecture 1 - Introduction

Module Convenor:
Dr. Md Enamul Hoque (PhD; NUS, Singapore)
Associate Professor
Office Room: BB38a; Tel: 03 8924 8367
Email: enamul.hoque@nottingham.edu.my

Module Aims
Introduce Context of New Product Introduction


Examine Technologies Available to:

Shorten Total Lead Time
Increase Confidence in Product

Discuss Factors Influencing Correct Choice of
Technologies
Assessment
Coursework:

30% of Total Credit


Exam:
70% of Total Credit
Past Years Students Performances
Session St. No. Min. No. Ave. No Max. No.
2008/09 54 41 64 75
2009/10 15 48 69.3 83.5

2010/11 14 60 69.3 80
2011/12 74 46 63.9 82
In Favor of Efficient Teaching & Learning
Strongly Recommended:
Regular attendance to lecture
Timely arrival and leaving the class
Active participation in the class (i.e. paying attention to
the lecture & responding to the questions etc.)
Deactivation of the phone etc.
Not Appreciated:
X Talking mutually
X Sitting in a casual mode
X Consuming foods/drinks
Strictly Prohibited: Sign on the attendance sheet for others
References

Journals
Rapid Prototyping Journal
Journal of Materials Processing Technology
Materials & Design
Websites
http://www.wohlersassociates.com
http://www.garpa.org
http://home.att.net/~castleisland/links.htm
http://www.cc.utah.edu/~asn8200/rapid.html
http://www.twi.co.uk/technologies/welding-coating-and-material-
processing/additive-manufacture/selective-laser-melting/
http://www.additive3d.com/sls.htm
http://www.scribd.com/doc/78576679/18/THE-SHAPE-DEPOSITION-
MANUFACTURING-PROCESS


6
Concepts and
Introduction
Module Structure
Product
Requirements
Prototyping
Rapid
Prototyping
Rapid
Tooling
Virtual
Prototyping
Rapid
Manufacturing
Responsive
Manufacturing
Reverse
Engineering
Introduction to Rapid
Product Development
Introduction
This session aims to set the context for the
whole Rapid Product Development module

It will become clear that many tools are
available for RPD

Only a subset of these tools will be covered
during the module
Product Development
Product development needs to be
considered at two levels:
Development of existing products
New product development

The first largely involves design improvement,
the second involves new design.

Both should be in response to customer
requirements.
Additive Manufacturing and
Rapid Prototyping
Fabrication Processes
Subtractive material removed from a block
(blank) to produce the desired shape (milling,
turning)

Compressive material formed into desired
shape (casting, moulding)

Additive material joined/added to produce
desired shape (Rapid Prototyping)
Subtractive Processes
Material removed from a block (blank) to
produce the desired shape (milling, turning)
13
Compressive Processes
Material formed into desired shape (casting,
forging, moulding)
14
Additive Processes
Can build Prototypes, Tooling or Finished
Products.

Starts from 3D CAD, CT Scans, MRI Scans, 3D
Digitising Systems.

Join Liquid, Powder or Sheet Material Layer -
by Layer Based on Thin Cross Sections of
the Electronic Model.

Products May be Metal, Plastic, Ceramic or
Composite Parts.
Additive Processes Early History

Rapid Prototyping
Late 1960s. Twin Lasers to solidify liquid Polymer.

Rapid Tooling/Rapid Manufacturing
Late 1970s. Cutting of Cross sections with Milling
Machine or Laser then Stacking Sheets
16
Additive Processes - History
Started in 1987
3D Systems in USA introduced SLA
(Stereolithography)
1988 Japanese SLA System NTT Data CMET
1989 Japanese SLA System Sony/D-MEC
1990 Electro Optical Systems (EOS) in
Germany
1990 Quadrax. 1991 Bankrupt due to
Litigation.
Additive Processes - History
1991 3 non SLA Technologies Commercialised
Fused Deposition Modelling (FDM) by
Stratasys
Solid Ground Curing(SGC) by Cupital
Laminated Object Manufacture (LOM) by
Helisys
Cupital and Helisys no Longer in Business
Additive Processes - History
1992 Selected Laser Sintering (SLS) by DTM
(now part of 3D Systems)
1993 Direct Shell Production Casting (DSPC)
by Soligen
1994 Inkjet Printing of wax
1996 Z Corp Starch and Plaster 3D Printer
1998 Optomec LENS, Sprayed Metal Powder
2000 Colour 3D Printer, Z Corp
Thank You

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