Manufacturing Engineering and Technology By Quentin Allen Angelo

Manufacturing Engineering and Technology By: Quentin Allen Angelo Juniel

Rapid Prototyping and Processes and Operations • Technologies associated with rapid prototyping. • Materials used with rapid prototyping. • Revolutionary practice of applying rapid-prototyping techniques to the production of tooling that can be used in other manufacturing processes.

Key Terms • ACES • BIBLIOGRAPHY • Electron-beam melting • Bibliography 549 • Photopolymer • Solid-ground curing • Additive processes • Sprayed metal tooling • Free-form fabrication • Stereolithography • Polyjet • Subtractive processes • Ballistic-particle • Three-dimensional printing • Fused-deposition modeling • Virtual prototyping • Prototype • manufacturing Keltool • Rapid tooling • Desktop machines • Laminated-object RTV molding/urethane • Direct AIM manufacturing casting • Direct manufacturing Multijet modeling Selective laser sintering

Developing a New Product • In a manufacturing process, prototyping is used as an example before the finished product. • There are 3 main reasons we use prototyping. 1. Capital cost 2. Design evaluation 3. Troubleshooting

Rapid Prototyping • Rapid prototyping is used to speed up the development process, so a final product can be introduced into the market quicker. • Rapid prototyping or RP is also known as desktop manufacturing, digital manufacturing and solid free form fabrication.

Rapid Prototyping example 3 d printed gear shift prototype • Ford Motor company saves more than $500, 000 annually and months of lead time through 3 d printing rapid prototyping process.

Major groups of Rapid prototyping • There are three types of prototyping processes. 1. Subtractive Process- involves material removal from a work piece that is larger than the final part. 2. Additive Process – build up a part by adding material incrementally to produce the part. 3. Virtual Process – uses advance computer based visualization technologies.

Subtractive Process- involves material removal from a work piece that is larger than the final part.

Additive Process Additive process – build up a part by adding material incrementally to produce the part.

Virtual Process – uses advance computer based visualization technologies

Subtractive Process • The Subtractive Process can take weeks or months to produce a product. • Part Complexity or size • Machine operator kill • Machine availability • There are several computer-based technologies the speed up process. • Computer Based Drafting Packages – which can product 3 D representations of parts. • Interpretation software – which can translate the CAD file into useable manufacturing software. • Manufacturing Software – which is capable of planning the operations required to produce a desire shape. • Computer-numerical-control machinery – with the capabilities nessacy to product produce.

Additive Process The Additive process only takes a few minutes to an hour to produce a part. • Due to setup and finishing operations that are very labor high intensive. • Sanding • Painting Additive operations require CAD software. Here a few additive manufacturing technologies. • Fused-deposition modeling(FDM) a gantry robot, that moves in 2 directions on a table. • Stereo lithography(STL) principles of curing a liquid photopolymer into a specific shape. • Multijet/Polymer Modeling(MPM) User UV bulbs, alongside jets they immediately cure each layer.

Additive manufacturing technologies • MIT lists additive manufacturing as one of the top ten breakthrough technologies. • GE chooses electric beam melting, to create its jet engine prototypes. • These technologies have been proven to reduce production cost, faster development, and reserves unused materials.

Other additive technologies • Sensor laser sintering- allows materials to be sintered, using a laser beam and CAD software programs. The materials are usually non metallic and metallic powders. • Electric beam melting – is used when a piece is produced in a vacuum tube, with electron beam scanning. • Three Dimensional Printing – uses a print head process to create inorganic products. Its commonly related to printing a binder onto powder. • Laminated object manufacturing – consists of using control software and vinyl cutters to develop a prototype. LOM is similar to creating sheets of paper with a CNC machine but more economically beneficial.