Search Results for rapid prototyping

Rapid prototyping (RP) techniques in the sheet-metal forming industry is developed to quickly test the form and fit of new sheet-metal products on a prototype basis as well as for production runs characterized by small lot sizes. This article provides an overview of some of the technologies used for RP and low-volume production of sheet-metal parts. It discusses low-cost tooling and flexible sheet-forming processes and reviews the various aspects of incremental sheet forming.

This article reviews various rapid prototyping (RP) processes such as stereolithography, powder sintering, hot melt extrusion, sheet lamination, solid ground curing, and three-dimensional printing. It discusses the various material prototypes produced by RP technology. The list of materials includes particulate and fiber-reinforced polymers, ceramic-matrix composites, and metal-matrix composites. The article also provides information on freeform-fabrication techniques for composite part lay-up.

Rapid prototyping (RP) is a field in manufacturing involving techniques/devices that produce prototype parts directly from computer-aided design models in a fraction of time. This article discusses the principles of RP and three major commercial processes, based on their layer creation method. These include selective cure layered processes, extrusion/droplet deposition processes, and sheet form fabricators. The article provides information on the three classes of RP, namely, voxel sequential volume addition, periphery cutting, and area sequential volume addition. It presents equations that represent build times for each of the three classes.

This article provides general guidelines for casting design to provide progressive solidification, minimize heat concentration, eliminate cores, and prevent distortion. Casting design also affects tolerances. Casting tolerances depend on the alloy being poured, the size of the casting, and the molding method used. Designers can predict the effect of the design on the structure of the final part using solidification simulation models, namely finite element and finite difference models, and rapid prototyping. The article concludes with a short note on how the quality is assured in the foundry.

Additive manufacturing (AM), also referred to as three-dimensional printing or rapid prototyping, is a set of technologies that has rapidly evolved and has drawn much research attention in the manufacturing of high value-added products. This article focuses on dentistry, one of the fields in which AM has gained much traction. It discusses the AM processes used to produce dentures, crowns, and bridges. Digitization techniques, which are the first step and provide the CAD model for AM processes, are presented. Scanning technologies that are widely used in dental manufacturing are presented in detail, and the strengths and weaknesses of each process within their applications are discussed. AM processes are discussed in detail, and the materials that are widely used in AM-embedded dental manufacturing are briefly surveyed. The final section concludes with remarks and a preview of future research and practice directions.

This article describes two rapid tooling technologies, namely, direct rapid tooling and indirect rapid tooling, for forging-die applications. Commonly used direct rapid tooling technologies include selective laser sintering, three-dimensional printing, and laser-engineered net shape process. The indirect rapid tooling technologies include 3D Keltool process, hot isostatic pressing, rapid solidification process tooling, precision spray forming, and radially constricted consolidation process.

Sheet forming comprises deformation processes in which a metal blank is shaped by tools or dies, primarily under the action of tensile stresses. This article discusses the classification of sheet-forming processes for obtaining desired dimensional features. It describes different process-related developments, namely, superplastic forming of aluminum, forming of tailor-welded blanks, rubber-pad forming, and high-velocity metal forming. The article explains cost-effective approaches of evaluating tooling designs prior to the manufacture of expensive steel dies and dieless forming techniques such as thermal forming and peen forming. It provides information on the application of advanced high-strength steels, magnesium alloys, and various ultrafine-grain materials for superplastic sheet forming. The article concludes with information on the development and application of simulation, design, and control of sheet-forming processes.

An ankle-foot orthosis (AFO) is a support designed to regulate the ankle's position and mobility, compensate for weakness, or rectify abnormalities. This article focuses on the biomechanical affects and mechanical properties of custom-made 3D-printed AFOs and compares them to traditionally created AFOs. Investigations in the fields of 3D scanning, 3D printing, and computer-aided design and analysis for the production of custom-made AFOs are also covered.

This article focuses on powder bed fusion (PBF) of ceramics, which has the potential to fabricate functional ceramic parts directly without any binders or post-sintering steps. It presents the results of three oxide ceramic materials, namely silica, zirconia, and alumina, processed using PBF techniques. The article discusses the challenges encountered during PBF of ceramics, including nonuniform ceramic powder layer deposition, laser and powder particle interactions, melting and consolidation mechanisms, optimization of process parameters, and presence of residual stresses in ceramics after processing. The applications of PBF ceramics are also discussed.

This article provides highlights of the general process and workflow of creating a 3D-printed model from a medical image and discusses the applications of additively manufactured materials. It provides a brief background on Food and Drug Administration (FDA) classification and regulation of medical devices, with an emphasis on 3D-printed devices. Then, the article discusses two broad applications of 3D printing in craniofacial surgery: surgery and education. Next, it discusses, with respect to surgical applications, preoperative planning, use in the operating room, surgical guides, and implants. The article includes sections on education that focus on the use of 3D-printed surgical simulators and other tools to teach medical students and residents. It briefly touches on the FDA regulations associated with the respective application of 3D printing in medicine. Lastly, the article briefly discusses the state of medical billing and reimbursement for this service.

This article introduces the design and manufacturing implications of additive manufacturing (AM) on part characteristics as well as on design opportunities and on manufacturing practices, supply chains, and even business models. In addition, it describes how they relate to the fundamental nature of AM processes and discusses the characteristics and purposes of AM processes and the parts they fabricate.

This article discusses the various roles and responsibilities of materials engineers in a product realization organization and suggests different ways in which materials engineers may benefit their organization. It also provides a summary of the concepts discussed in the articles under the Section “The Role of the Materials Engineer in Design” in ASM Handbook, Volume 20: Materials Selection and Design.

This article provides an introduction to the additive manufacturing (AM) terminology. The article describes the input and output of the AM process. It explains AM process categories, providing comments on the international standard on AM terminology, ISO/ASTM 52900.

Additive manufacturing is a collection of manufacturing processes, each of which builds a part additively based on a digital solid model. The solid model-to-additive manufacturing interface and material deposition are entirely computer-controlled. The traditional additive manufacturing applications have been used for low production runs of parts with complex shapes and geometric features. Additive manufacturing is also used for topology optimization and it impacts the process and supply chain. This article discusses processes, including vat photopolymerization, material jetting, powder bed fusion, directed energy deposition, material extrusion, binder jetting, and sheet lamination.