MDMD Rapid Product Development

Transcription

1 MSc in Manufacturing and Welding Engineering Design - Dr.-Eng. Antonios Lontos Department of Mechanical Engineering School of Engineering and Applied Sciences Frederick University 7 Y. Frederickou Str., Nicosia 1036, Cyprus eng.la@frederick.ac.cy, lontosantonios@gmail.com Web: Ch Fig.: 1

2 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 Ch Fig.: 2

3 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 Ch Fig.: 3

4 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. Ch Fig.: 4

5 Assessment method Assignments: 100% Course Assignment Real rapid product development problem Recommended and/or required reading 1. Rapid prototyping, Principles and applications, 2. Additive Manufacturing Technologies, Gibson Ian, Rosen David, Springer, New York, Chua C.K, Leong K.F, Lim C.S, Rapid Prototyping Principles and Applications, World Scientific, New Jersey, Bartolo, Jorge Paulo, Virtual and Rapid Manufacturing, Taylor And Francis, London, 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 Introduction - About the course Ch Fig.: 5

6 Assessment methods and criteria Assignments: 100% Description Assessment Grade (%) 1. Effort - Time spent on project Writing skills - Is the writing text adequate? English language, text format, pictures, drawing, diagrams Main body - Extensive, accurate and appropriate details Methodical approach to the design and manufacturing development. Good approach of the designing methods and manufacturing processes Enthusiastic - The student was interested about his work Conclusion and results - Are the final results and conclusions well defined and analytically explained? Learning outcome - The scientific and professional skill of the student was increased during the elaboration of the project? Overall quality - What is the overall quality of the project? 10 Overall 100% GRADE: A (86-100), B (76-85), C (66-75), D (56-65), E (50-55) Introduction - About the course Ch Fig.: 6

7 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) Introduction - About the course Ch Fig.: 7

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9 MSc in Manufacturing and Welding Engineering Design - 1. Introduction Dr. Antonios Lontos Website: eng.la@frederick.ac.cy, lontosantonios@gmail.com Ch Fig.: 1

10 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. Ch Fig.: 2

11 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. Ch Fig.: 3

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13 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 Ch Fig.: 5

14 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 Ch Fig.: 6

15 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 Ch Fig.: 7

16 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 Ch Fig.: 8

17 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. Ch Fig.: 9

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