Rapid Prototyping & Manufacturing (RP&M)

Robert P. Jackson, P.E.

Course Outline

This four (4) hour course will examine the following subject matter and strive to provide the reader with more than a basic understanding of the uses, benefits, methodology, materials and processes involved with the technology:

• Introduction to Rapid Prototyping—What is this all about?
• Industries Using PR&M Today—What companies are ahead of the curve? Who is using the technology?
• What Processes Represent RP&M Technology—There are six (6) basic processes.
• Basic Processes—The very basic steps in the technology itself and how those apply to each methodology.
• Industry Applications –The classification of uses for the processes.
• Photographs Showing Industry Applications—What component designs are suited for RP&M fabrication?
• Benefits of Using RP&M Technology—Why should we even consider using PR&M over traditional methods to produce prototypes?
• The Downside of RP&M Technology—Cautions involved with use of the technology.
• History of Rapid Prototyping—Evolution or revolution?
• Definition and Comparison of Processes
•  Schematics Detailing the Mechanics for Each Methodology—We look at each of the five methods for producing prototypes and discuss the mechanics of each.
• Chemistry, Selected Materials and Photopolymers
• Mechanical Properties of Photopolymers
• Vendors—Selected companies in the industry.
• Laser Technology Needed for Processes—Laser types used today.
• Software—What software drives the industry?
• Standards
• Future Developments—Where is the industry going and what might we expect?
• Summary
• Glossary of Terms
• Specification Sheets for Selected Materials
• References
  

This course includes a multiple choice quiz at the end, which is designed to enhance the understanding of the course materials.

Learning Objective

At the completion of this course the student will have accomplished the following:

• Developed an understanding for the many benefits rapid prototyping can provide to manufacturing, medical, dental, building, construction, archeology, paleontology and other professions;
• Have an appreciation for the history and development of rapid prototyping technology;
• Know the differences between rapid prototyping systems and which system provides the greatest benefit for a specific application: i.e. stereolithograhy, laminated object manufacturing, selective laser sintering, fused deposition modeling, etc.;
• Have and understand examples of prototypes possible when using the technology;
• Will know and understand the five (5) most important questions to ask when contemplating the use of the technology;
• Know and understand the necessary steps in the RP&M (Rapid Prototyping and Manufacturing) process. There is a great deal of preparation needed prior to selecting an RP&M method.  We will definitely explore the necessary steps prior to making that decision;
• Have an understanding of basic polymer chemistry and why some materials are best suited for specific RP&M methods;
• Have an understanding of the mechanical and physical properties of the materials available for each prototyping process;
• Know how to read material specification sheets and have examples of what information is given when using a material spec sheet;
• Have the ability to compare the RP&M processes;
• Have an understanding of laser types and laser operation relative to the RP&M additative processes;
• Have an understanding of the three (3) laser types that drive the processes;
• Have information for the relative costs of each process and a basis for comparing each process from a financial standpoint;
• Have an appreciation of the software necessary to drive the various system and processes and the basic minimums needed prior to selecting a prototyping method;
• An appreciation for the surface finishes possible with each RP&M method;
• An appreciation for the accuracy possible with each RP&M method;
• Have a complete glossary of terms relative to the total technology;
• Have a representative list of vendors participating in the technology today;
• Know what post-forming operations are possible; and
• Have a complete list of references for further study.

Intended Audience

This four (4) hour course is intended for individuals participating in the following professions:

• Engineering Managers
• Mechanical Engineers
• Design Engineers
• Draftspersons; i.e. CAE and CAD Technicians
• Quality Engineers
• Quality Control Inspectors
• Manufacturing Engineers
• Machinists
• Individuals involved with providing parts from model shop operations
• Green, Black or Master Black Belt practitioners
• Reliability Engineers
• Medical Practitioners
• Mold Makers
• Medical Research Teams
• Doctors Involved with Dental Surgery
• Producers of Video Games
• Designers of Jewelry

We are covering material that would definitely benefit practitioners of those professions given above.  Rapid prototyping methodologies are used when component parts and samples are needed very quickly to demonstrate form, fit and function and to prove or disprove the viability of a design approach.   There are several processes that can produce components allowing for complete analysis of specific concepts and possibly forestall “false starts” relative to consumer and marketing needs.

Benefit to Attendees

The purpose of this four (4) hour course is to provide necessary information so an individual will gain an appreciable understanding of the technology.  This certainly includes operational parameters, hardware and the necessary software to drive the system of components.  The course is structured to go beyond the basics and make it possible for a potential user to gain knowledge that will facilitate informed conversations with material suppliers, software specialists and vendors.  The most important benefit is the ability to choose between PR&M methodologies so that the choice is proper for the outcome.   To support the text, we provide a comprehensive glossary of terms integral to an understanding of the technology.  After successful completion, an individual will have a much broader ability to recognize possible applications for the technology and communicate that need to suppliers in the industry.

Course Introduction

Rapid prototyping is definitely a technology that has, and is, changing the way companies and commercial entities do business.   We can certainly say this “emerging technology” has gained tremendous momentum over the past decade.  The applications and uses represent a “best practice” for manufacturers and producers in general.  
Being able to obtain prototype parts quickly allows a company to test for component form, fit and function and can help launch a product much faster than your competition.   This can allows for adjustments in design, materials, size, shape, assembly, color and manufacturability of individual components and subassemblies.   Rapid prototyping is one methodology that allows this to happen.   It also is an extremely valuable tool for sales and marketing evaluation at the earliest stages of any program.   Generally, an engineering scope study is initially performed in which all elements of the development program are evaluated.  Having the ability to obtain parts “up front” provides a valuable advantage and definitely complements the decision making process.   Several rapid prototyping processes are available for today’s product design teams while other prototyping processes utilize traditional manufacturing methods, such as 1.)  CNC Machining, 2.)  Laser Cutting, 3.)  Water Jet Cutting, 4.) EDN Machining, etc.   Rapid prototyping technologies emerged in the ‘80s and have improved considerably over a relatively short period of time.   There are several viable options available today that take advantage of rapid prototyping technologies.   All of the methods shown below are considered to be examples of rapid prototyping and manufacturing technologies. 

• (SLA) Stereolithography
• (SLS) Selective Laser Sintering
• (FDM) Fused Deposition Modeling
• (3DP) Three Dimensional Printing
• (Pjet) Poly-Jet
• Laminated Object Manufacturing

This course addresses each of these RP&M technologies and provides a full description of each method of production as well as the materials used for each.

Course Content

The course content is in a PDF file:

Rapid Prototyping & Manufacturing (RP&M)

Please click on the above underlined hypertext to view, download or print the document for your study. Because of the large file size, we recommend that you first save the file to your computer by right clicking the mouse and choosing "Save Target As ...", and then open the file in Adobe Acrobat Reader. If you still experience any difficulty in downloading or opening this file, you may need to close some applications or reboot your computer to free up some memory.

Course Summary

Rapid Prototyping and Manufacturing (RP&M) has been written to demonstrate that the methodologies described represent “best practices” and provide a much faster and more cost-efficient way to obtain samples, regardless of the component.  This is a four (4) hour course that gives, in detail, descriptions of those electromechanical systems which provide the engineer, marketing manager, doctor, theatrical set designer, dentist, etc. solid, tangible models from which to analyze and plan.  The subject matter will include but not be limited to the following areas of study:

• Description of each method, including the hardware designed to provide the model.
• Pictorial examples of components manufactured by the various processes.
• Software options that drive the systems.
• Benefits and drawbacks from considering RP&M methodologies.
• List of vendors participating in the industry today.
• Description of the chemistry and materials integral to the processes.
• Complete glossary of terms and definitions.
• What industries use RP&M?

This is an exciting field and one in which more and more companies are moving into.  The options for saving time and money relative to prototyping needs are truly significant.

Quiz

Once you finish studying the above course content, you need to take a quiz to obtain the PDH credits.

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DISCLAIMER: The materials contained in the online course are not intended as a representation or warranty on the part of PDH Center or any other person/organization named herein. The materials are for general information only. They are not a substitute for competent professional advice. Application of this information to a specific project should be reviewed by a registered architect and/or professional engineer/surveyor. Anyone making use of the information set forth herein does so at their own risk and assumes any and all resulting liability arising therefrom.

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