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Monday, 15 July 2013

RAPID PROTOTYPING BY MOSES DHILIP KUMAR

RAPID PROTOTYPING



This document provides a detailed description and a brief understanding about the rapid prototyping.

THEME: Enhancing the detailed importance and need of RAPID PROTOTYPING in the society.
Introduction
Rapid prototype is an excellent output from the thirst of millions of scientist , the main promotion of the model lies in its skill where it reduces the time for experimenting an model without much cost and effort.

DEFENITION


ORIGIN
Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. The first techniques for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts. Today, they are used for a much wider range of applications and are even used to manufacture production-quality parts in relatively small numbers.

WORKING
With additive manufacturing, the machine reads in data from a CAD drawing and lays down successive layers of liquid, powder, or sheet material, and in this way builds up the model from a series of cross sections. These layers, which correspond to the virtual cross section from the CAD model, are joined together or fused automatically to create the final shape. The primary advantage to additive fabrication is its ability to create almost any shape or geometric feature.
The standard data interface between CAD software and the machines is the STL file format. An STL file approximates the shape of a part or assembly using triangular facets. Smaller facets produce a higher quality surface.
INTERFACING
The standard data interface between CAD software and the machines is the STL file format. An STL file approximates the shape of a part or assembly using triangular facets. Smaller facets produce a higher quality surface.
SIGNIFICANCE
Rapid Prototyping has also been referred to as solid free-form manufacturing, computer automated manufacturing, and layered manufacturing. RP has obvious use as a vehicle for visualization. In addition, RP models can be used for testing, such as when an airfoil shape is put into a wind tunnel. RP models can be used to create male models for tooling, such as silicone rubber molds and investment casts. In some cases, the RP part can be the final part, but typically the RP material is not strong or accurate enough. When the RP material is suitable, highly convoluted shapes (including parts nested within parts) can be produced because of the nature of RP.

HELPFUL AREAS
Used in in-house utilities
Used in comparative analysis
Used in comprehensive testing
TECHNOLOGICAL INNOVATIONS THAT OVERTOOK THE DIFFICULTIES AFTER THE INVENTION OF RAPID PROTOTYPE



BEFORE                    AT PRESENT
An complete model is done for experimental and for a testing purpose
Just an prototype is desingned so that it can be tested and can be used for the consultation of betterment
An extensive time period is spent in the dept of testing
A lot of time and power has been saved
Cost of production is increased which reduces its popularity.
Cost of production is much reduced.
In case of difficulty in the existing model it cannot be replaced immediately with out complete comprehensive test .
In case of any difficulty it can be easily verified and also can be rectified using the designed prototype.
If the tested model is failure due to some design model it is not that easy to create such an another model
But in the prototype it is much easier .

Good prototype model


OLD METHOD OF TESTING


Modern ways of testing

PROTOTYPE’S SIGNIFICANCE:

Increasingly companies are attaching greater importance to the need to differentiate their product and service offerings in order to remain competitive. Typically, firms are:
adding new technologies to our products to differentiate;
forming alliances with our   customers;
adding service features to our manufactured product offerings;
reducing time to market for new products;
reducing the number of suppliers and forming longer-term relationships and alliances with those that remain;
expanding the product range; and reducing their cost base to become the lowest cost producer.










MAIN DISADVANTAGES OF RAPID PROTOTYPE :
When dealing rapid prototyping technologies, seven major strategic issues need to be explored
The strategic nature of the technologies - aspects of rapid prototyping which take investment decisions beyond the realm of short-term return on investment calculations;
The technologies as enablers of new strategies - the new business and marketing strategies that can be pursued as a result of using these technologies;
The impact of rapid prototyping on the achievement of business objectives - the specific business objectives that can be directly affected by applying the technologies;
Strategic aspects of organisational and cultural changes - what organisational and culture changes does the business strategy itself demand;
Development of change competencies - applying rapid prototyping technologies to achieve operational change competency, and developing tactical and strategic change competencies to enable continuing developments in rapid prototyping to be deployed to satisfy existing business objectives and to develop new strategies;
Development and exploitation of knowledge - using existing knowledge and developing new knowledge for competitive advantage.




WHY WE NEED IT:
The sale of this product with others because it is much easier to see if there are problems with the design and organization of a real working model
It is also much easier to sell to potential customers when they have a rapid prototyping to hold and manipulate a presentation marketing.
 Without a prototype is just an idea.
 It can be difficult to get a client to participate in a purchase of one concept.
With prototype in hand, the concept becomes real and the moment is much easier .
We  should keep in mind during the prototype phase as well. Regardless of how developers and testers that a prototype can be, consumers may not real, as some of its aspects.
 If the end customer does not like, they will not buy, which explains why the focus groups and external tests with the prototypes to be addressed before production begins.
 Patent If a product is new or unique bit excessive, patents must be considered.
It is useless to design and produce a great product to another company only begins to produce a product very similar, because the original company patented key design elements.
Having a working prototype is much easier to sit with a lawyer to see what aspect of the design may be patentable.
 On the back, you can see parts of the prototype and the design of infringing patents of others and how they can be changed before production, and the possibility of a trial begins.

BASIC LEVEL OF A COMPLETE PROTOTYPING MODEL AND A FLOW CHART SCENARIO.

 














INCONVINIENCE IN USING RAPID PROTOTYPING MACHINE:

Needs co operation of workers to finish an complete model successfully.

Higer officials may consider prototyping as an wasteful needed process

Programmer may loose discipline

The prototype may influence the design

The pror=totype model may be overworked.




LUXURY OF PROTOTYPE



Unattended operation

This system is fully automated that is doesn‘t require any attention
during the operation.

Good accuracy

The SLA able to produce a very high accuracy
˜
0.001“



High detailing

SLA is capable of producing an intricate design with high precision.

Surface finish

The —printed part“ has a very smooth surface.

Industry presence

SLA was the first RP to be introduced into the market. It constituted
1% of the worldwide market based on sales.
The part may melt if exposed to high temperature for a period of time.


 

 Influence of design by rapid prototype

The prototype may have an influence on your design which should be taken care of.



A GOOD MODEL
AN AVERAGE MODEL





STEPS TO REDUCE THE ABOVE MENTIONED INCONVINIENCE:

The material chose should be apt and easily adoptable.

The material chosen should always be in an position to be cooled fast by the cooler used.

The complication of the prototype should be reduced in the stl files used.



CONCLUSION:



Henceforth being well aware of this engineering excellence of a rapid prototype ,  being an engineer we should be well enough acquired to readily accept the advancement in such area which would greatly enhance our career.

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