Package 2: Rapid Prototyping Tools

Suggeste
Category Name Description d Type
Quantity

1.75 mm PLA Printer, With

Rapid 3D Printer 180mm ×200mm ×160mm
Equipmen
Prototyping Kit and Build Volume, Spatula, 1
t
Tools tools Tweezers, Cutter, Screwdriver,
Wrench etc.

Rapid Filament
1.75mm PLA filament. 750-1000 Consumab
Prototyping for 3D 5
g spools le
Tools printer

18 | P a g e

Cardboard,
foam core
boards,
5
Set of Arts & Crafts string,
Rapid
Accessories – eg- stationary rubberband, Consumab
Prototyping 5 50m
items and basic prototyping popscicle le
Tools 100 100 1
material sticks,
btl assort
wood glue,
balsawood
sheets &rods

What is Prototyping

What is 3D Printing?
3D printing or additive manufacturing (AM) technologies create
three-dimensional parts from computer-aided design (CAD) models by
successively adding material layer by layer until physical part is
created.
While 3D printing technologies have been around since the 1980s,
recent advances in machinery, materials, and software have made 3D
printing accessible to a wider range of businesses, enabling more
and more companies to use tools previously limited to a few high-
tech industries.
Today, professional, low-cost desktop and benchtop 3D printers
accelerate innovation and support businesses in various industries
including engineering, manufacturing, dentistry, healthcare,
education, entertainment, jewelry, and audiology.

How Does 3D Printing Work?

All 3D printing processes start with a CAD model that is sent to software to prepare the design. Depending
on the technology, the 3D printer might produce the part layer by layer by solidifying resin or sintering
powder. The parts are then removed from the printer and post-processed for the specific application.

1. Design

3D printers create parts from three-dimensional models, the

mathematical representations of any three-dimensional surface
created using computer-aided design (CAD) software or developed
from 3D scan data. The design is then exported as an STL or OBJ
file readable by print preparation software.
3D printers include software to specify print settings and slice
the digital model into layers that represent horizontal cross-
sections of the part. Adjustable printing settings include
orientation, support structures (if needed), layer height, and
material. Once setup is complete, the software sends the
instructions to the printer via a wireless or cable connection.

2. 3D Print

Some 3D printers use a laser to cure liquid resin into hardened

plastic, others fuse small particles of polymer powder at high
temperatures to build parts. Most 3D printers can run unattended
until the print is complete, and modern systems automatically
refill the material required for the parts from cartridges.
3. Post-Process

Depending on the technology and the material, the printed parts

may require rinsing in isopropyl alcohol (IPA) to remove any
uncured resin from their surface, post-curing to stabilize
mechanical properties, manual work to remove support structures,
or cleaning with compressed air or a media blaster to remove
excess powder. Some of these processes can be automated with
accessories.
3D printed parts can be used directly or post-processed for
specific applications and the required finish by
machining, priming, painting, fastening or joining. Often, 3D
printing also serves as an intermediate step alongside
conventional manufacturing methods, such as positives for
investment casting jewelry and dental appliances, or molds for
custom parts.

The Benefits of 3D Printing

As additive manufacturing processes build objects by adding material layer by layer, they offer a unique
set of advantages over traditional subtractive and formative manufacturing processes.

Speed
With traditional manufacturing processes, it can take weeks or months to receive a part. 3D printing turns
CAD models into physical parts within a few hours, producing parts and assemblies from one-off concept
models to functional prototypes and even small production runs for testing. This allows designers and
engineers to develop ideas faster, and helps companies to bring products more quickly to the market.

Cost
With 3D printing, there’s no need for the costly tooling and setup associated with injection molding or machining;
the same equipment can be used from prototyping to production to create parts with different geometries. As 3D
printing becomes increasingly capable of producing functional end-use parts, it can complement or replace
traditional manufacturing methods for a growing range of applications in low- to mid-volumes.

Customization
From shoes to clothes and bicycles, we’re surrounded by products made in limited, uniform sizes as businesses
strive to standardize products to make them economical to manufacture. With 3D printing, only the digital design
needs to be changed to tailor each product to the customer without additional tooling costs. This transformation
first started to gain a foothold in industries where custom fit is essential, such medicine and dentistry, but as 3D
printing becomes more affordable, it’s increasingly being used to mass customize consumer products.

Design Freedom
3D printing can create complex shapes and parts, such as overhangs, microchannels, and organic shapes, that
would be costly or even impossible to produce with traditional manufacturing methods. This provides the
opportunity to consolidate assemblies into less individual parts to reduce weight, alleviate weak joints, and cut
down on assembly time, unleashing new possibilities for design and engineering.
Reduced Risk
Product development is an iterative process that requires multiple rounds of testing, evaluation, and refinement.
Finding and fixing design flaws early can help companies avoid costly revisions and tooling changes down the
road. With 3D printing, engineers can thoroughly test prototypes that look and perform like final products,
reducing the risks of usability and manufacturability issues before moving into production.

Applications and Uses of 3D Printing

Engineering and Product Design

Rapid prototyping with 3D printing empowers engineers and product designers to turn ideas into realistic proofs
of concept, advance these concepts to high-fidelity prototypes that look and work like final products, and guide
products through a series of validation stages toward mass production.

Applications:

•Rapid prototyping
•Communication models
•Manufacturing validation

Manufacturing
Manufacturers automate production processes and streamline workflows by prototyping tooling and directly 3D
printing custom tools, molds, and manufacturing aids at far lower costs and lead times than with traditional
manufacturing. This reduces manufacturing costs and defects, increases quality, speeds up assembly, and
maximizes labor effectiveness.

Applications:

•Jig and fixtures

•Tooling
•Molding (injection molding, overmolding)
•Metal casting
•Short run production
•Mass customization

Dental
Digital dentistry reduces the risks and uncertainties introduced by human factors, providing higher consistency,
accuracy, and precision at every stage of the workflow to improve patient care. 3D printers can produce a range
of high-quality custom products and appliances at low unit costs with superior fit and repeatable results.

Applications:

•Crown and bridge models

•Clear aligner and Hawley retainer models
•Surgical guides
•Splints and occlusal guides
•Patterns for casting and pressing
•Dentures
Education
3D printers are multifunctional tools for immersive learning and advanced research. They can encourage
creativity and expose students to professional-level technology while supporting STEAM curricula across science,
engineering, art, and design.

Applications:

•Models for STEAM curricula

•Fab labs and makerspaces
•Custom research setups

Healthcare
Affordable, professional-grade desktop 3D printing helps doctors deliver treatments and devices customized to
better serve each unique individual, opening the door to high-impact medical applications while saving
organizations significant time and costs from the lab to the operating room.

Applications:

•Anatomical models for surgical planning

•Medical devices and surgical instruments
•Insoles and orthotics

Entertainment
High definition physical models are widely used in sculpting, character modeling, and prop making. 3D printed
parts have starred in stop-motion films, video games, bespoke costumes, and even special effects for
blockbuster movies.

Applications:

•Hyper-realistic sculptures
•Character models
•Props

Jewelry
Jewelry professionals use CAD and 3D printing to rapidly prototype designs, fit clients, and produce large batches
of ready-to-cast pieces. Digital tools allow for the creation of consistent, sharply detailed pieces without the
tediousness and variability of wax carving.

Applications:

•Lost-wax casting (investment casting)

•Fitting pieces
•Master patterns for rubber molding

Audiology
Hearing specialists and ear mold labs use digital workflows and 3D printing to manufacture higher quality
custom ear products more consistently, and at higher volumes for applications like behind-the-ear hearing aids,
hearing protection, and custom earplugs and earbuds.

Applications:

•Soft silicone ear molds

•Custom earbuds
3D Printing Technologies: An Overview

1. Stereolithography (SLA)
Stereolithography makes use of a liquid plastic as the source material and this
liquid plastic is transformed into a 3D object layer by layer1. Liquid resin is
placed in a vat that has a transparent bottom. A UV (UltraViolet) laser traces a
pattern on the liquid resin from the bottom of the vat to cure and solidify a
layer of the resin. The solidified structure is progressively dragged up by a
lifting platform while the laser forms a different pattern for each layer to create
the desired shape of the 3D object3.

2. Fused Deposition Modeling (FDM)

With this technology, objects can be built with production-grade
thermoplastics1. Objects are built by heating a thermoplastic filament to its
melting point and extruding the thermoplastic layer by layer. Special
techniques can be used to create complex structures. For example, the printer
can extrude a second material that will serve as support material for the object
being formed during the printing process1. This support material can later be
removed or dissolved.
3. Selective Laser Sintering (SLS)
SLS has some similarities with Stereolithography. However, SLS makes use of
powdered material that is placed in a vat. For each layer, a layer of powdered
material is placed on top of the previous layer using a roller and then the
powdered material is laser sintered according to a certain pattern for building
up the object to be created. Interestingly, the portion of the powdered
material that is not sintered can be used to provide the support structure and
this material can be removed after the object is formed for re-use1.
4. Digital Light Processing (DLP)

5. Selective Laser Melting (SLM)

6. Electronic Beam Melting (EBM)

7. Laminated Object Manufacturing (LOM)

FDM 3D Printing materials compared

1. Dremel DigiLab 3D45 3D Printer
Max Buit Area : 6.7 by 10 by 6 inches (HWD)

2. MakerBot Replicator
3. Ultimaker S5

4. Flashforge Finder 3D Printer Review

5. FormLabs
6. HP high end costly Printers

FDM Printers Good Brands

Choosing Good 3 D Printer with given specification