MDMD 512 - Rapid Product Developmentstaff.frederick.ac.cy/eng.la/MDMD512 Rapid Product...Rapid...

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Rapid Product Development MDMD 512

MDMD 512 - Rapid Product Development

Dr.-Eng. Antonios Lontos

Department of Mechanical Engineering

School of Engineering and Applied Sciences

Frederick University

7 Y. Frederickou Str., Nicosia 1036, Cyprus

E-mail: [email protected], [email protected]

Web: http://staff.fit.ac.cy/eng.la

MSc in Manufacturing and Welding Engineering Design

mailto:[email protected]


http://staff.fit.ac.cy/eng.la

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Table of Contents

Chapter 01: Introduction

Chapter 02: Rapid product development and tools

Chapter 03: Rapid prototyping technologies

Chapter 04: Laser scanners and computer tomography

Chapter 05: Reverse engineering

Chapter 06: Rapid tooling

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Learning outcomes of the course unit

• Discussing the wide variety of new rapid prototyping technologies such as liquid or solid based rapid

prototyping systems.

• Apply rapid prototyping technologies in product development

• Be able to use 3D printing, stereolithography, selective laser sintering, and fused deposition modeling to the

product development process.

• Be able to design, optimize, manufacture, and validate a physical system component.

• Use additive manufacturing as an automated technique for direct conversion of 3D CAD data into physical

objects using a variety of approaches

• Be able to select the appropriate rapid prototyping technology in the automotive, aerospace, medical, and

consumer products industries

Introduction - About the course

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Course contents:

• Rapid Prototyping process. Process chain, 3D Shape Technologies, 3D modelling, Software Engineering,

Digital Representation of Shapes, 3D laser scanners and surface generation, Computer tomography and

Solid creation, Different algorithms to represent solid objects. Rapid prototyping data formats, Data

conversion and transmission, Postprocessing.

• Rapid Prototyping Techniques. Stereolithography, Three-dimensional models from liquid photosensitive

polymers, Stereolithography apparatus (SLA) machines, Laminated Object Manufacturing, adhesive-coated

sheet material, Selective Laser Sintering, Laser beams, Fused Deposition Modeling, Solid Ground Curing, 3-

D Ink-Jet Printing

• Liquid, solid and powder based rapid prototyping. 3D Systems, Models and specifications, Processes and

principles, Microfabrication, Deposition Manufacturing process.

• Applications of Rapid Prototyping. Applications in design, engineering, Analysis and planning, Applications in

manufacturing and tooling, Aerospace, automotive, biomedical, Jewellery industry.

• Future Developments. Technical evaluation through benchmarking, Industrial growth, Accuracy improvement

and surface finish, Use of new materials like non-polymeric materials, metals, ceramics and composites,

Distance Manufacturing on Demand, Further developments trends.

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Recommended and/or required reading

1. Rapid prototyping, Principles and applications,

2. Additive Manufacturing Technologies, Gibson Ian, Rosen David, Springer, New York, 2010

3. Chua C.K, Leong K.F, Lim C.S, Rapid Prototyping Principles and Applications, World Scientific, New

Jersey, 2005

4. Bartolo, Jorge Paulo, Virtual and Rapid Manufacturing, Taylor And Francis, London, 2008

5. Manufacturing Engineering and technology, Six Edition, Serope Kalpakjian, Steven R. Schmid, Prentice

Hall

6. Manufacturing Processes for Engineering Materials, Fifth Edition, Serope Kalpakjian, Steven R. Schmid,

Prentice Hall

Course Assignment

• Real rapid product development problem

Assessment method

• Assignments: 100%


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Assessment methods and criteria

Assignments: 100%

GRADE: A (86-100), B (76-85), C (66-75), D (56-65), E (50-55)


Description – Assessment Grade (%)

1. Effort - Time spent on project 10

2. Writing skills - Is the writing text adequate? English language, text format,

pictures, drawing, diagrams 10

3. Main body - Extensive, accurate and appropriate details 40

4. Methodical approach to the design and manufacturing development. Good

approach of the designing methods and manufacturing processes 10

5. Enthusiastic - The student was interested about his work 5

6. Conclusion and results - Are the final results and conclusions well defined

and analytically explained? 5

7. Learning outcome - The scientific and professional skill of the student was

increased during the elaboration of the project? 10

8. Overall quality - What is the overall quality of the project? 10

Overall 100%

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Aims

To produce engineering designers with "concurrent engineering" capability, integrating materials and

manufacturing process selection into a structured design methodology based on the application of basic

engineering and scientific principles. Emphasis on design creativity.

Outline

• Design Communication (CAD, solid modelling)

• Design Methodology (design process, customer focus, integration of engineering science)

• Prototyping (processes and their selection, materials selection, costs)


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End of Chapter

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MSc in Manufacturing and Welding Engineering Design

MDMD 512 - Rapid Product Development

1. Introduction

Dr. Antonios Lontos Website: http://staff.fit.ac.cy/eng.la/

E-mail: [email protected], [email protected]

http://staff.fit.ac.cy/eng.la/



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• Rapid Product Development will prepare students for entry-level jobs in the drafting industry.

• Learn how products are brought to market – from concept to the finished product.

• Use 3D CAD software to design their product and transform the virtual design to a physical

object using rapid manufacturing processes.

• Included sketching, drafting, design, and 3D computer applications on PC computer systems

using SolidWorks software and 3D printers that produce rapid prototype models.

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Meet the needs of specialized applications, including:

Design Prototypes

3D print concept models, functional prototypes and presentation models for evaluating and

refining designs, including finite element analysis (FEA) results and packaging.

Education

Engage students by bringing digital concepts, into the real world, turning their ideas into

real-life 3D color models that they can actually hold in their hands.

Architecture

Create models of architectural designs and prototypes for the design of critical elements.

Industrial

Make patterns and molds for metal casting, RTV molding and urethane casting applications.

Entertainment and the Arts

Produce custom avatars and figurines from 3D data generated by electronic games — and other

creations — with ease.

Geospatial

Easily convert GIS data into 3D landscape and cityscape models.

Healthcare

Rapidly produce 3D models to reduce operating time, enhance patient and physician

communications, and improve patient outcomes.

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3D Systems, producers of the world’s fastest, easiest-to-use and most affordable color 3D printers,

Produce physical color models quickly, easily and inexpensively from computer-aided design (CAD)

and other digital data. The most successful companies have adopted 3D printing as a critical part of

the iterative design process to:

Increase Innovation

• Print prototypes in hours, obtain feedback, refine designs and repeat the cycle until designs

are perfect

• Create affordable prototypes early in the ideation stage of product development

Improve Communication

• Hold realistic 3D models in your hands to impart infinitely more information than a computer

image

• Communicate with various audiences using fast, affordable and easy 3D printing

Speed Time to Market

• Compress design cycles by 3D printing multiple prototypes on demand, right in your office

Reduce development Costs

• Cut traditional prototyping and tooling costs

• Identify design errors earlier

• Reduce travel to production facilities

Win Business

• Bring realistic 3D models to prospective accounts, sponsors and focus groups

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3D printer Advantages

High speed and throughput for a range of applications

• Output models in hours, not days

• Build multiple models at the same time

• Support an entire engineering department or classroom with ease

Color and high quality dramatically communicate design intent

• Produce realistic color models without paint

• Better evaluate the look, feel, and style of product designs

• 3D print text labels, logos, design comments, or images directly onto models

• A range of options, from 64 basic colors to unlimited color combinations

• Multiple print heads provide the best range of accurate and consistent colors high resolution

Realistic models and precise details

• High-definition 3D printing produces models with complex geometries and small, detailed

features

• 3D print the most intricate detail, such as a thin wall on a mechanical prototype or a railing on

an architectural model

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Affordable for all environments

• Unused materials are recycled for the next build, eliminating waste

• Based on reliable, affordable inkjet technology

Spend time generating ideas, not operating a 3D printer

• Requires minimal training and expertise

• Only ZPrinters perform most operations automatically

• Automated setup and self monitoring

• Automated powder loading and recycling

• Snap-in binder cartridges

• Intuitive control panel for easy operation

Ideal for everyday use in any standard office or school environment

• Quiet, safe, odor free

• Closed-loop powder loading, removal, and recycling

• Eco-friendly, non-hazardous build material

• No physical support structures to remove with dangerous cutting tools or toxic chemicals

• Noise-suppression technologies for quiet, intrusion-free operation

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Various RP Methods

• Photo curing

• Cutting and joining

• Melting

• Solidifying / fusing

• Joining / binding

Materials

• Solid

• Liquid

• powder

Applications

• Design

• Engineering analysis and planning

• Tooling and manufacturing

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Advances of rapid prototyping

Direct benefits (experiment with physical objects)

Benefits to Product Designers

Increase part complexity with less time and cost

Benefits to the tooling and manufacturing Engineers

Savings in cost. Minimize design, manufacturing and verification of tooling

Benefits of marketing

New capabilities and opportunities

Benefits to the consumers

Special products to customers needs. Products built to order.

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