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Reverse Engineering &

Rapid Prototyping

Lab-2

METEOROLOGY & MACHINING LAB

SUMIT JADHAV

ME10B017 | Lab-2

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OBJECTIVE:

To reverse engineer a specimen and rapid prototype it. Learning about fusion deposition method of RPT

and to learn about laser scanning.

APPARATUS REQUIRED:

Sample material, FARO laser scanner, Fusion deposition machine.

THEORY:

Fusion deposition is an additive Rapid manufacturing technology in which molten layers of plastic is

deposited through a nozzle. It is a process which required support material so two nozzles are present.

The process starts by processing the .stl(stereo lithography file) by a software. The software develops a

layer by layer structure of the file with the supply of required support materials. This process can

generate layers as thin as 0.04 mm. The prototype is constructed layer by layer. The nozzles are heated

to melt the wire feed and is deposited.

FAROs laser scanner is used for scanning the 3D model to the system. Laser scanner basically sends an

optical signal and accepts it back upon reflection. So this makes it difficult to read black as well as white

bodies.

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PROCEDURE:

1. The given 3D model is scanned in to the computer using FARO laser scanner.2. The scanned model is then converted to .stl format and is processed.3. The 3D printer is switched on and is kept for warming up.4. The processed file is imputed to the 3D printer.5. The 3D printer makes the 3D model.

OBSERVATIONS:

1. There are two nozzles present for the 3D printer one for depositing support material and one fordepositing the thermoplastic.

2. The support material is light and less strong compared to the thermoplastic used for prototypingso it can be removed without damaging the original model.

3. The FARO laser scanner does not work for black as well as too bright materials.4. There is range of distance from the scanned object to the scanner. Being too close or too far, it

makes difficult for the machine to scan.

5. The CAM software is able to generate the layers as well as the support material all by itself.6. The support material nozzle and the thermoplastic nozzle works one at a time.7. The 3D printer need a warming up time in which it make the temperature of the base equal to

the temperature of the molten material so the sudden cooling and the wreckage doesnt take

place.

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RESULT:

A given 3D model is successfully scanned using FARO laser scanner and is regenerated on a 3D printerwhich works on the principle of Fusion deposion.

CONCLUSION:

1. The fusion deposition method is a fast Rapid prototyping process.2. The time consumed for the process is high which is disadvantage.3. Almost any shape can be generated on fusion deposition based 3D printing.4. The thin layer thickness (0.04mm) makes it possible to generate very fine details.5. The laser scanning technique is very effective in generating the exact replica of a 3D object.