Rapid Prototyping Rapid Tooling And Reverse Engineering

This book introduces the role of Rapid Prototyping Techniques within the product development phase. It deals with the concept, origin, and working cycle of Rapid Prototyping Processes with emphasis on the applications. Apart from elaboration of engineering and non-engineering applications, it highlights recent applications like Bio-Medical Models for Surgical Planning, Molecular Models, Architectural Models, Sculptured Models, Psycho-Analysis Models. Special emphasis has been provided to the technique of generating human organs from live cells/tissues of the same human named 3D BIO PRINTERS. As the Rapid Prototyping Techniques are for tailor made products and not for mass manufacturing hence the book also elaborates on the mass manufacturing of rapid prototyped products. This includes casting and rapid tooling. The book concludes with Reverse Engineering and the role played by Rapid Prototyping Techniques towards the same. With globalization of market and advances in science and technology, the life span of products has shortened considerably. For early realization of products and short development period, engineers and researchers are constantly working together for more and more efficient and effective solutions. The most effective solution identified has been usage of computers in both designing and manufacturing. This gave birth to the nomenclatures CAD (Computer Aided Designing) and CAM (Computer aided Manufacturing). This was the initiation that ensured short product development and realization period. Researchers coined the concept as Rapid Prototyping. In contrast to Prototyping, Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing or "additive or subtractive layer manufacturing" technology. The first methods for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts. Today, they are used for a wide range of applications and are used to manufacture production-quality parts in relatively small numbers if desired without the typical unfavorable short-run economics. This economy has encouraged online service bureaus for early product realization or physical products for actual testing. This book is expected to contain Seven Chapters. Chapter 1 would explain product life cycle and the product development phase in the same, introducing role of Rapid Prototyping Techniques in Product development phase. Chapter 2 would deals with the concept, origin and working cycle of Rapid Prototyping Processes. Chapter 3 would concentrates on the applications of Rapid Prototyping Technology. Apart from elaboration of engineering and non-engineering applications, it also elaborates on recent applications like Bio-Medical Models for Surgical Planning, Molecular Models, Architectural Models, Sculptured Models, Psycho-Analysis Models etc. Chapter 4 would introduce the various Rapid Prototyping systems available worldwide. The chapter also introduces the technique of generating human organs from live cells/tissues of the same human named 3D BIO PRINTERS hence ensuring low rejection rate by human body. As the Rapid Prototyping Techniques are for tailor made products and not for mass manufacturing hence Chapter 5 would elaborates on the mass manufacturing of rapid prototyped products. This includes Casting and Rapid Tooling. Chapter 6 would deal with Reverse Engineering and the role played by Rapid Prototyping Techniques towards the same. As the product realization is primarily dependent on various softwares which are required to be understood for better accuracy so the concluding chapter of the book i.e. Chapter 7 would explain some software associated with the various techniques.

Time compression technologies such as rapid prototyping and manufacturing offer enormous potential benefits. Where time can be saved in the development of new or modified products, expenditure can also be reduced. Swifter development can also give a competitive edge to those using these techniques. However there are a number of different systems and processes that can be used. Ensuring that the most appropriate rapid prototyping and manufacturing technology is applied to a problem is vital to the success of a project. The case studies, compiled by the experienced team of the Warwick Manufacturing Group at the University of Warwick in the UK, represent a range of different real experiences drawn from a variety of industries, using a range of materials and processes. CONTENTS INCLUDE: Overview of product design and development Computer-aided design and rapid prototyping The introduction of CAD/CAM in the ceramics industry Product design and development – reverse engineering Reducing the risk of new product development by utilizing rapid prototyping technologies Stress analysis using rapid prototyping techniques Case studies in rapid prototyping and manufacturing techniques–flow visualization using rapid prototype models Overview of utilizing bureau facilities Using bureau services Running an internal rapid prototyping bureau Overview of rapid casting techniques An alternative route to metal components for prototype and low-volume production Rapid prototyping in pattern making and foundry applications Rapid prototyping – enhancing product development at Parker Hannifin Cast tooling with rapid prototype patterns Overview of rapid tooling The role of rapid immediate production tooling (IPT) in new product development Rapid tooling – cast resin and sprayed metal tooling.

Up-to-date documentation on the current scope of the research of Rapid Prototyping, Tooling and Manufacturing. Explains and details the latest techniques and materials used for RP, RT and RM. Develops methodologies and technologies to support in a customer-focused product design and mass customization approach to production.

Since the dawn of civilization, mankind has been engaged in the conception and manufacture of discrete products to serve the functional needs of local customers and the tools (technology) needed by other craftsmen. In fact, much of the progress in civilization can be attributed to progress in discrete product manufacture. The functionality of a discrete object depends on two entities: form, and material composition. For instance, the aesthetic appearance of a sculpture depends upon its form whereas its durability depends upon the material composition. An ideal manufacturing process is one that is able to automatically generate any form (freeform) in any material. However, unfortunately, most traditional manufacturing processes are severely constrained on all these counts. There are three basic ways of creating form: conservative, subtractive, and additive. In the first approach, we take a material and apply the needed forces to deform it to the required shape, without either adding or removing material, i. e. , we conserve material. Many industrial processes such as forging, casting, sheet metal forming and extrusion emulate this approach. A problem with many of these approaches is that they focus on form generation without explicitly providing any means for controlling material composition. In fact, even form is not created directly. They merely duplicate the external form embedded in external tooling such as dies and molds and the internal form embedded in cores, etc. Till recently, we have had to resort to the 'subtractive' approach to create the form of the tooling.

Rapid prototyping is an exciting new technology used to create physical models and functional prototypes directly from CAD models. Rapid tooling concerns the production of tooling using parts manufactured by rapid prototyping. The book describes the characteristics and capabilities of the main known rapid prototyping processes. It covers in detail various commercially available processes such as: Stereolithography (SLA), Selective Laser Sintering (SLS), and others. The text places a strong emphasis on practical applications and contains an abundance of photographs and diagrams to illustrate clearly the principles of the machines and processes involved.

A discussion of the rapid tooling (RT) technologies under development and in use for the timely production of moulds and manufacturing tools. It describes applications within various leading companies and guides product and manufacturing process development groups on ways to reduce investments of money and time.

User's Guide to Rapid Prototyping will help designers, engineers, executive management, and others in the company understand how to apply rapid prototyping technologies such as 3D printing, stereo-lithography, selective laser sintering, and fused deposition modeling to the product development process. Intertwined with rapid prototyping, the processes of rapid tooling and rapid manufacturing are also discussed. An aid to making informed business decisions, the book provides information about when it may be right to implement rapid prototyping in-house versus going to a service provider. The path through justification, evaluation, and implementation is outlined. Readers will gain insights into the benefits, risks, and limitations of each technology.

Rapid Prototyping and allied fields are still relatively young technologies and, as such, their scope and range are expanding at a dramatic rate. New and improved techniques and applicationsare developing and this is reflected in the varied topics covered in Rapid Design, Prototyping and Manufacture. Efforts to extend the scope of application of three dimensional printing processes is an important milestone in rapid manufacture. This is being vigorously addressed and is well represented in this volume. It now seems to be only a matter of time before three-dimensional printing units will join other peripherals in office and domestic computer systems to produce toys, small domestic and office items on demand. CONTENTS INCLUDE: Analysis of the application of the Z-corps three dimensional printing system for rapid tooling for plastic injection moulded components. A novel method for rapid prototyping/tooling/manufacture - Shell/Assisted Layer Manufacture (SALM) Accuracy of a novel fused deposition modelling technology New software tools for reverse engineering parts based on three-dimensional volumetric scans. A stuctured approach to the simplification of optimization problems in the virtual prototyping environment The appropriate application of computer-aided design and manufacture techniques in silicone facial prosthetics Application of the Z-Corps three-dimensional printing processes using novel material to manufacture bio-scaffold for bone replacement Rapid prototyping manufacture of complex three-dimensional microscaffolds used in regenerative medicine.