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Rapid DevelopmentRapid Development
David P PollockDavid P Pollock28 JUN 0628 JUN 06
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AgendaAgenda
• What is Rapid Prototyping (RP)? What is Rapid Prototyping (RP)? • Why use RPWhy use RP• RP TechnologiesRP Technologies• Integrating RP TechnologyIntegrating RP Technology• QuestionsQuestions
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What is Rapid What is Rapid Prototyping?Prototyping?What is Rapid What is Rapid Prototyping?Prototyping?
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Rapid prototypingRapid prototyping
• Communications tool• Additive or subtractive process• Growing parts introduced in 1987• Parts of any geometric complexity• Rapid tooling• VOC
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Rapid prototypingRapid prototyping
• Additive not intended to replace all methods of part fabrication
• Limited material choices - additive• Parts will not be as durable• May require extensive secondary finishing
operations
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Why use RP?Why use RP?Why use RP?Why use RP?
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Rapid prototypingRapid prototyping
• A six month delay in production start can result in a 66% loss in gm*
• 80% of costs of NPD before detailed drawings released*
• VOC – LEAN• Touch, feel, hold vs. 3D model
*Copyright © 2002-2006 T. A. Grimm & Associates, Inc. All rights reserved.
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Rapid prototypingRapid prototyping• Easy• Efficient
– Concurrent engineering
• Accessible• Iterations
– Communicate ideas
– VOC
– Sales
– Packaging
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RP TechnologiesRP TechnologiesRP TechnologiesRP Technologies
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Additive Rapid PrototypingAdditive Rapid Prototyping
Build-up process• 3-D Printing• Fused Deposition Modeling• Stereolithography• Selective Laser Sintering• Jetted Photopolymer
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• Developed by MIT
• Powder-adhesive process
• Lowest cost technology
• Five times faster
• Limited materials
Rapid prototypingRapid prototyping
3-Dimensional Printing3-Dimensional Printing
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• Similar to 3-D printing
• Fast for very small parts
• Suitable for office use
• Polymer filament ribbon
• Engineered materials: ABS, PC, PPS
Fused Deposition Modeling - FDMFused Deposition Modeling - FDM
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• Most widely used process
• Largest part size
• High accuracy
• Good surface finish
• Liquid polymer – laser cured
• Part size up to
29” x 25” x 21”29” x 25” x 21”
Stereolithography - SLAStereolithography - SLA
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• Large part size
• High accuracy
• Post-forming operations
• Engineered resins – highest strength
• Autoclave capable
• Lower surface quality compared to SLA
Selective Laser Sintering - SLSSelective Laser Sintering - SLS
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• Similar to inkjet printing
• UV curable resin
• Lower cost than SLA
• Suitable for office use
• Thin build layer – little post build finishing
Jetted Photopolymer System - PolyJetJetted Photopolymer System - PolyJetTMTM
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Subtractive Rapid Prototyping - SRPSubtractive Rapid Prototyping - SRP
Material removal process• 4-axis high-speed mill
– Lower equipment cost
– Non-proprietary materials
– No post-finishing
– Bridge tooling
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Integrating RP Integrating RP TechnologyTechnology
Integrating RP Integrating RP TechnologyTechnology
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Rapid DevelopmentRapid Development
Innovation CenterInnovation Center• Experimental design facility• Manufacture one-off samples and small lot parts• Easy-to-use equipment eliminating need for machinist• Rapid prototyping equipment
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Rapid DevelopmentRapid Development
Partnership - Hybrid TechnologyPartnership - Hybrid Technology• Partner with capable supplier• Combine rapid machining with subtractive technology• Capacity exclusivity• Production level parts in production materials• Bridge tooling to manufacturing
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Special Thanks:Special Thanks:Special Thanks:Special Thanks:
Todd Grimm, TA Grimm & Associates
Photo Credits: Castle Island Co., All Rights Reserved.