Experimenting with Rapid Prototyping

Experimenting withRapid PrototypingDr. Jim FlowersTechnology Education ProgramBall State University

and Something Called

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Rapid Prototyping Technology canHelp your students make professional-quality products without all those skillsMake a link between digital designs and physical objectsAllow students to make successive changes to designs, and then see the effects of those changesProduce parts needed for larger assemblies

Ball States Rapid Prototyping Lab Technologies Include

3D Laser Scanning

Last photo: Wireframe of Scanned Shell by Rachel Shettle4Laser Cutting & Engraving

CAD/CAM Milling

Computer Numerical Control Turning(NC Lathe)

Fused Deposition Modeling

Color Solid Object Printing

House Model by Whitney Warner9Other Technologies in the RP LabTensile testerCoordinate measuring machinePlastics granulator, drier, and filament extrudersManual fabrication toolsVacuum formersBut RP technologies can also support student experimentation.They allow the user to control several variables and perform repeated builds changing only the levels of independent variables.There is so much we really dont know, and experimentation can help us find the answers.For example: Optimizing Laser SettingsPowerSpeedFocal PointPulses per inchLines per inch

An Experimental Approach to Everything

Orr, T., & Flowers, J. (2014). An experimental approach to everything! Technology & Engineering Teacher, 73(8), 8-12.

Determining the effect of FDM build orientation on tensile strength (T. Orr)

Hey Jim, can you 3D print onto cloth? (Rene Church)Kyle Samuels, a student in a graduate course on Inquiries into Rapid Prototyping, at Ball State found out.

Samuels, K., & Flowers, J. (In Press). Can your students 3D print onto cloth? Technology and Engineering Teacher.

Successful build test at materials surfaceFailed attempt on 100% cotton with a simple weavePost wash testDenim adhesion strength testCan you make 3D printer filament?Orr, T., & Flowers, J. (In Press). Learning through plastic filament extrusion. Technology and Engineering Teacher.

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Image from www.filabot.com Image from www.filastruder.com Can you use RP to createFlexographic Image Carriers?

Dr. Renmei XuFlowers, J., & Xu, R. (April, 2011). Exploring a connection: Prototyping graphic image carriers. Technology and Engineering Teacher e, 70(7), 1-6.Xu, R. & Flowers, J. C. (2009). Flexographic platemaking using rapid prototyping technologies. FlexoGlobal, 2 (1), 24-30. Flexo- Image Carriers fromPowdered Solid Object Printing?

Flexo- Image Carriers from FDM?

Flexo- Image Carriers from Laser Engraving?

Can you laser-etch an intaglio plate?

Xu, R., Londt, S., & Flowers, J. (2013). The effects of laser-engraving settings on clich etch depth and pad printing quality. Journal of Print and Media Technology Research, 2(1), 29-35.

Can you laser-etch an intaglio plate?

Can you laser-etch an intaglio plate? Yes, but what are the effects of laser-engraving settings on clich etch depth and pad printing quality?

Can lasers be used to create stencils?Xu, R., Londt, S. C., Kellogg, H. P. (2010). Evaluation of different stencilmaking methods for screen printing (pp. 228-242). Sewickley, PA: Proceedings of TAGA 62nd Annual Technical Conference.

Can lasers be used to create stencils?Yes, but what is the effect of

Can you Upcycle with a laser?

Xu, R., Flowers, J. (2011). Engineering a greener process: Laser cutter transforms printing waste. Tech Directions, 71(2), 20-23.

Can you Upcycle with a laser?

Can you Upcycle with a laser?

Can you Upcycle with a laser?

AdvertisementNew undergrad and grad class at Ball State:Green Prototyping & Upcycling, where studentsDesign, prototype, and test products to promote environmental sustainabilityUpcycle with laser cutters/engraversAttempt to extrude their own 3D filament from post-consumer resins and 3D print with itMay be used as an elective in our Master of Arts in Technology EducationAssisting others in their research:Kevin Barnes & Kamal IslamScanned warbler model3D printed 10 decoysDecoys were painted and added to buckets playing songs to attract cerulean warblers to nest.

Kevin Barns, 2014, Master of Science Thesis Project: Cerulean Warbler Habitat Selections: Behavioral or Structural. Kamal Islam, PhD, Advisor.Photos of Kevin and Kamal courtesy of Kamal Islam at http://kislam.iweb.bsu.edu/Cerulean%20Warbler%20Research.htm

So many experiments!Optimizing parametersEffects of parameters on productsProperties based on build orientationDesigning new 3D printer filamentAdding inserts during 3D printingAdhesion, finishing, etc., of 3D printed partsTesting out new processesand many, many moreCustom Intersections