Department of Mechanical Engineering

IV BTECH I SEM R20 (Open Elective - 3) JNTUK

Course Objectives

1) To understand the principles of prototyping, classification of RP processes and liquidbased RP systems 

2) To understand and apply different types of solid-based RP systems. 

3) To understand and apply powder-based RP systems. 

4) To understand and apply various rapid tooling techniques. 

5) To understand different types of data formats and to explore the applications of AM processes in various fields. 

Course Outcomes

At the end of the course, student will be able to 

CO1: Understand the principles of prototyping, classification of RP processes and liquid-based RP systems. 

CO2: Understand and apply different types of solid-based RP systems. 

CO3: Apply powder-based RP systems 

CO4: Analyze and apply various rapid tooling techniques. 

CO5: Understand different types of data formats and explore the applications of AM processes in various fields. 

Course Content

UNIT– I: INTRODUCTION: Prototyping fundamentals, historical development, fundamentals of rapid prototyping, advantages and limitations of rapid prototyping, commonly used terms, classification of RP process. 

LIQUID-BASED RAPID PROTOTYPING SYSTEMS: Stereo lithography Apparatus (SLA): models and specifications, process, working principle, photopolymers, photo polymerization, layering technology, laser and laser scanning, applications, advantages and disadvantages, case studies. Solid Ground Curing (SGC): models and specifications, process, working principle, applications, advantages and disadvantages, case studies. 

UNIT– II: SOLID-BASED RAPID PROTOTYPING SYSTEMS: Laminated object manufacturing (LOM) - models and specifications, process, working principle, applications, advantages and disadvantages, case studies. Fused deposition modelling (FDM) - models and specifications, process, working principle, applications, advantages and disadvantages, case studies. 

UNIT– III: POWDER BASED RAPID PROTOTYPING SYSTEMS: Selective laser sintering (SLS): models and specifications, process, working principle, applications, advantages and disadvantages, case studies. three dimensional printing (3DP): models and specifications, process, working principle, applications, advantages and disadvantages, case studies. 

UNIT– IV: RAPID TOOLING: Introduction to rapid tooling (RT), conventional tooling Vs RT, Need for RT. rapid tooling classification: indirect rapid tooling methods: spray metal deposition, RTV epoxy tools, Ceramic tools, investment casting, spin casting, die casting, sand casting process. Direct rapid tooling: Direct AIM, LOM Tools, and Direct Metal Tooling using 3DP. 

UNIT– V: RAPID PROTOTYPING DATA FORMATS: STL Format, STL File Problems, consequence of building valid and invalid tessellated models, STL file Repairs: Generic Solution, other Translators, and Newly Proposed Formats. RP APPLICATIONS: Application in engineering, analysis and planning, aerospace industry, automotive industry, jewelry industry, coin industry, GIS application, RP medical and bioengineering applications: customized implants and prosthesis, forensic sciences. 

TEXT BOOKS: 

Rapid prototyping: Principles and Applications /Chua C.K., Leong K.F. and LIM C.S/World Scientific publications .

REFERENCES: 

1. Rapid Manufacturing / D.T. Pham and S.S. Dimov/Springer 

2. Wohlers Report 2000 /Terry T Wohlers/Wohlers Associates 

3. Rapid Prototyping & Manufacturing / Paul F.Jacobs/ASME Press 

4. Rapid Prototyping / Chua & Liou