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2001 | Buch

Introduction Kapitel lesen Erstes Kapitel lesen

Rapid Manufacturing

The Technologies and Applications of Rapid Prototyping and Rapid Tooling

verfasst von: D. T. Pham, BE, PhD, DEng, FREng, CEng, FIEE, S. S. Dimov, Dipl Eng, PhD

Verlag: Springer London

Enthalten in: Professional Book Archive

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Über dieses Buch

Rapid Manufacturing is a term that embraces rapid prototyping and rapid tooling.
Rapid prototyping is an exciting new technology for quickly creating physical models and functional prototypes directly from CAD models. Rapid tooling generally concerns the production of tooling using parts manufactured by rapid prototyping. Rapid prototyping and rapid tooling are means for compressing the time-to-market of products and, as such are competitiveness enhancing technologies.
The book describes the characteristics and capabilities of the main known rapid prototyping processes.
It covers in detail commercially available processes, such as:
- Stereolithography (SLA);
- Selective Laser Sintering (SLS);
- Fused Deposition Modelling (FDM);
- Solid Ground Curing (SGC);
- Laminated Object Manufacturing (LOM)
and provides information on several other processes still under development.
The book discusses various direct and indirect methods of producing soft tooling, firm tooling (or bridge tooling) and hard tooling based on rapid prototyping. The discussion is wide- ranging and not found in other books published to-date. Also special to the book is material on process optimisation. This was derived from work at the authors'Centre and is not available in other texts. The book places a strong emphasis on practical applications, devoting special chapters to both the applications of rapid prototyping and rapid tooling. The book contains an abundance of photographs and diagrams, some in colour, to illustrate clearly the principles of the machines and processes involved. The book does not require any special background. It should be of interest to manufacturing, industrial, production, mechanical and materials engineers wishing to up date themselves on some of the most important developments in modern manufacture. (The authors are from the Manufacturing Engineering Centre, which conducts leading-edge research into advanced manufacturing as well as providing a commercial rapid prototyping and tooling service to several hundred industrial customers).

Inhaltsverzeichnis

Frontmatter
Chapter 1. Introduction
Abstract
Global competition, customer-driven product customisation, accelerated product obsolescence and continued demands for cost savings are forcing companies to look for new technologies to improve their business processes and speed up the product development cycle. Rapid Prototyping (RP) has emerged as a key enabling technology with its ability to shorten product design and development time. RP technologies can be virtual and physical.
D. T. Pham, S. S. Dimov
Chapter 2. Rapid Prototyping Processes
Abstract
This chapter presents a classification of existing physical Rapid Prototyping (RP) processes along with an outline of each method. For convenience, the term RP will hereafter refer only to physical RP.
D. T. Pham, S. S. Dimov
Chapter 3. Technical Characteristics and Technological Capabilities of Rapid Prototyping Systems
Abstract
This chapter gives a technical overview of commercially available RP systems. In particular, the chapter examines the technical characteristics and application areas of systems based on the following RP processes: stereolithography, solid ground curing, fused deposition modelling, selective laser sintering, laminated object manufacturing and laser engineering net shaping. The main strengths and weaknesses of these systems are also reviewed. In addition, the chapter gives examples of different RP applications in which these commercially available systems have been successfully employed.
D. T. Pham, S. S. Dimov
Chapter 4. Technical Characteristics and Technological Capabilities of Concept Modellers
Abstract
This chapter gives a technical overview of commercially available Concept Modellers. These are a new range of RP systems addressing the specific needs of CAD offices. Although CAD systems have empowered designers with a number of tools to minimise errors and maximise design quality offering facilities such as photorealistic visualisation, interactive product simulation, assembly analysis, and kinematic and stress analysis, the design remains intangible until a physical model is built. Concept Modellers fill this gap by offering relatively quick and cost effective methods for building physical models at any design stage. They are marketed as new CAD peripheral solutions which enable designers to verify and iterate their designs without leaving the office. Typically, Concept Modellers build models more quickly but not so accurately as other RP systems and usually cost less than $50,000. The following RP systems are classed as Concept Modellers:
  • 3D Systems ThermoJet printer (Multi-Jet Modeller);
  • Sanders ModelMaker II (Inkjet Modelling Technology);
  • Z-Corporation Z402 (3D printer);
  • Stratasys Genisys Xs printer;
  • JP System 5;
  • Objet Quadra system.
D. T. Pham, S. S. Dimov
Chapter 5. Applications of Rapid Prototyping Technology
Abstract
Rapid Prototyping (RP) is a continuously evolving technology. RP models are becoming widely used in many industrial sectors. Initially conceived for design approval and part verification, RP now meets the need for a wide range of applications from building test prototypes with material properties close to those of production parts to fabricating models for art and medical applications. In order to satisfy the specific requirements of a growing number of new applications, special software tools, build techniques and materials have been developed. This chapter discusses the use of RP in five different application areas: building functional prototypes, patterns for castings, medical models, artworks and models for engineering analysis. In addition, the chapter outlines the technological capabilities of RP processes in the context of each particular application and discusses specific issues relating to the efficient integration of these techniques into existing manufacturing routes.
D. T. Pham, S. S. Dimov
Chapter 6. Indirect Methods for Rapid Tool Production
Abstract
As Rapid Prototyping (RP) is becoming more mature, material properties, accuracy, cost and lead-time are improving to permit it to be employed for the production of tools. Some traditional tool making methods based on the replication of models have been adapted and new techniques allowing tools to be made directly by RP have been developed. This chapter reviews indirect methods for rapid tooling (RT) that are, or shortly will be, available for production runs of up to several hundred parts in the same material as, or a material very similar to, that of the final production part. The RT methods presented below are called indirect because they use a RP pattern obtained by an appropriate RP technique as a model for mould and die making.
D. T. Pham, S. S. Dimov
Chapter 7. Direct Methods for Rapid Tool Production
Abstract
Indirect methods for tool production as described in the previous chapter necessitate a minimum of one intermediate replication process. This might result in a loss of accuracy and could increase the time for building the tool. To overcome some of the drawbacks of indirect methods, some RP apparatus manufacturers have proposed new rapid tooling methods that allow injection moulding and die-casting inserts to be built directly from 3D CAD models. This chapter describes direct RT solutions that are currently commercially available.
D. T. Pham, S. S. Dimov
Chapter 8. Applications of Rapid Tooling Technology
Abstract
The introduction of Rapid Tooling (RT) technology has enabled prototype, pre-production and in some cases full production tooling to be fabricated within significantly reduced time frames. In the previous Chapter several proprietary solutions for direct tool production were described. A sound understanding of the capabilities and limitations of these processes is essential in order to implement the technology successfully. This Chapter further discusses the DTM RapidTool process, which is one of the most significant direct tooling methods to be introduced in recent years, and from the experience gained with this process, some important lessons are highlighted, which apply to RT technology in general. Special attention is given to the specific design and finishing requirements of RapidTool inserts because these aspects have a critical effect in optimising the capabilities of the process. A study of the wear characteristics of RapidTool and EOSintM inserts is presented along with two industrial case studies which illustrate the application of RT technology in the fields of plastics injection moulding and aluminium gravity die-casting.
D. T. Pham, S. S. Dimov
Chapter 9. Rapid Prototyping Process Optimisation
Abstract
Initially conceived for design approval and part verification, RP now meets the needs of a much wider range of applications. In order to satisfy the requirements of these applications and broaden the area of application of RP, significant research and technology development is being directed towards process optimisation.
D. T. Pham, S. S. Dimov
Backmatter
Metadaten
Titel
Rapid Manufacturing
verfasst von
D. T. Pham, BE, PhD, DEng, FREng, CEng, FIEE
S. S. Dimov, Dipl Eng, PhD
Copyright-Jahr
2001
Verlag
Springer London
Electronic ISBN
978-1-4471-0703-3
Print ISBN
978-1-4471-1182-5
DOI
https://doi.org/10.1007/978-1-4471-0703-3