Rapid Manufacturing

1 Introduction.- 1.1 Historical Perspectives.- 1.2 Rapid Prototyping - An Integral Part of Time Compression Engineering.- 1.2.1 Geometrical Modelling Techniques.- 1.2.1.1 Wireframe Modelling.- 1.2.1.2 Surface Modelling.- 1.2.1.3 Solid Modelling.- 1.2.2 RP Data Formats.- 1.3 RP Information Workflow.- 1.4 Summary.- References.- 2 Rapid Prototyping Processes.- 2.1 Classification of Rapid Prototyping Processes.- 2.2 Processes Involving a Liquid.- 2.2.1 Solidification of a Liquid Polymer.- 2.2.1.1 Stereolithography (SL).- 2.2.1.2 Liquid Thermal Polymerization (LTP).- 2.2.1.3 Beam Interference Solidification (BIS).- 2.2.1.4 Objet Quadra Process (Objet).- 2.2.1.5 Solid Ground Curing (SGC).- 2.2.1.6 Holographic Interference Solidification (HIS).- 2.2.2 Solidification of an Electroset Fluid: Electrosetting (ES).- 2.2.3 Solidification of Molten Material.- 2.2.3.1 Ballistic Particle Manufacture (BPM).- 2.2.3.2 Multi Jet Modelling (MJM).- 2.2.3.3 Fused Deposition Modelling (FDM).- 2.2.3.4 Three Dimensional Welding (3DW).- 2.2.3.5 Shape Deposition Manufacturing (SDM).- 2.3 Processes Involving Discrete Particles.- 2.3.1 Fusing of Particles by Laser.- 2.3.1.1 Selective Laser Sintering (SLS).- 2.3.1.2 Laser Engineering Net Shaping (LENSTM).- 2.3.1.3 Gas Phase Deposition (GPD).- 2.3.2 Joining of Particles with a Binder.- 2.3.2.1 Three-Dimensional Printing (3DP).- 2.3.2.2 Spatial Forming (SF).- 2.4 Processes Involving Solid Sheets.- 2.4.1 Laminated Object Manufacture (LOM).- 2.4.2 Paper Lamination Technology (PLT).- 2.4.3 Solid Foil Polymerisation (SFP).- 2.5 Summary.- References.- 3 Technical Characteristics and Technological Capabilities of Rapid Prototyping Systems.- 3.1 Stereolithography Apparatus (3D Systems).- 3.2 Solid Ground Curing Systems (Cubital Ltd).- 3.3 Fused Deposition Modelling Systems (Stratasys, Inc.).- 3.4 Selective Laser Sintering Systems (DTM Corp. and EOS GmbH).- 3.5 Laminated Object Manufacturing Systems (Helisys, Inc.).- 3.6 Paper Lamination Technology (Kira Corp).- 3.7 Laser Engineering Net Shaping (LENSTM) Systems (Optomec Design Co.).- 3.8 Summary.- References.- 4 Technical Characteristics and Technological Capabilities of Concept Modellers.- 4.1 3D Systems ThermoJetT Printer.- 4.2 Sanders ModelMaker II (Inkjet Modelling Technology).- 4.3 Z-Corporation Z402 3D Printer (Three Dimensional Printing).- 4.4 Stratasys Genisys Xs 3D Printer.- 4.5 JP System 5.- 4.6 Objet Quadra System.- 4.7 Summary.- References.- 5 Applications of Rapid Prototyping Technology.- 5.1 Functional Models.- 5.2 Pattern for Investment and Vacuum Casting.- 5.3 Medical Models.- 5.4 Art Models.- 5.5 Engineering Analysis Models.- 5.6 Summary.- References.- 6 Indirect Methods for Rapid Tool Production.- 6.1 Role of Indirect Methods in Tool Production.- 6.2 Metal Deposition Tools.- 6.3 RTV Tools.- 6.4 Epoxy Tools.- 6.5 Ceramic Tools.- 6.6 Cast Metal Tools.- 6.7 Investment Casting.- 6.8 Fusible Metallic Core.- 6.9 Sand Casting.- 6.10 KeltoolT Process.- 6.11 Summary.- References.- 7 Direct Methods for Rapid Tool Production.- 7.1 Classification of Direct Rapid Tool Methods.- 7.2 Direct ACEST Injection Moulds (AIMT).- 7.3 Laminated Object Manufactured (LOM) Tools.- 7.4 DTM RapidToolT Process.- 7.4.1 RapidSteel 1.0.- 7.4.2 RapidSteel 2.0.- 7.4.3 Copper Polyamide (PA).- 7.5 SandFormT.- 7.6 EOS DirectToolT Process.- 7.7 Direct Metal Tooling using 3DPT.- 7.8 Topographic Shape Formation (TSF).- 7.9 Summary.- References.- 8 Applications of Rapid Tooling Technology.- 8.1 Insert Design.- 8.2 Insert Finishing.- 8.3 Rapid Tooling Inserts Wear Resistance.- 8.3.1 Wear Test Results.- 8.3.1.1 Non-coated RapidSteel 2.0 Insert.- 8.3.1.2 Non-coated EOSINT M Insert.- 8.3.1.3 Spray-coated Inserts.- 8.3.2 Discussion of the Wear Test Results.- 8.4 Case Studies.- 8.4.1 ABS Portable Electronic Tour Guide.- 8.4.2 Aluminium Windscreen Wiper Arm.- 8.5 Summary.- References.- 9 Rapid Prototyping Process Optimisation.- 9.1 Factors Influencing Accuracy.- 9.1.1 Data Preparation.- 9.1.1.1 Errors due to Tessellation.- 9.1.1.2 Errors due to Slicing.- 9.1.2 Part Building.- 9.1.2.1 Part Building Errors in the SL Process.- 9.1.2.2 Part Building Errors in the SLS Process.- 9.1.3 Part Finishing.- 9.2 Selection of Part Build Orientation.- 9.2.1 Orientation Constraints of the SL Process.- 9.2.2 Orientation Constraints of the SLS Process.- 9.3 Summary.- References.- Author Index.