The Influence of Depth of Cut, Feed Rate, and Step-over on Dimensional Accuracy in Subtractive Rapid Prototyping of Polycarbonate Material

Subtractive rapid prototyping is fast and automatic three dimensions physical modelling that uses computer aided design model as the input. The dimensional accuracy of the result of the subtractive rapid prototyping is influenced by its process parameters. The aim of this research is to study and then develop a model that shows the influence of depth of cut, feed rate, and step-over on the vertical length error, horizontal length error, and depth error in subtractive rapid prototyping of polycarbonate material. This research implements response surface methodology to develop the model and then followed by the residual tests to evaluate the developed model. The result shows that the increase of the feed rate and the step-over will increase the horizontal dimension error. The most influenced factor on the horizontal dimension error is the step-over. Meanwhile, the vertical dimension error will be affected mostly by the step-over. Last, the depth error is influenced by the feed rate, the step-over, and the depth of cut. The depth of cut is the most critical factor that increases the depth error. The developed models give an insight on how several process parameters of rapid prototyping will influence the dimensional accuracy of a polycarbonate material. Based on the model, efficient resources utilization can be achieved

Volume Modeling for Rapid Prototyping

The expanding workspace of Rapid Prototyping will draw on the new developments in geometric modeling. Volume modeling has substantial advantages over other modeling schemes to meet the emerging requirements of Rapid Prototyping technology. It provides us with a new approach to design complex geometry and topology. The integration of the volume modeling and Rapid Prototyping technology will help us to fully exploit RP's ability to fabricate objects with complex structures. This paper addresses our research and practice in a volume modeling system toward Rapid Prototyping. Novel techniques in volumetric data manipulation, NURBS volume models and triangular facet generation over solid models are presented. Computer models designed by this system and their corresponding DTM products are also shown atthe end of this paper.Mechanical Engineerin

Initial thoughts on rapid prototyping techniques

This paper sets some context, raises issues, and provides our initial thinking on the characteristics of effective rapid prototyping techniques.After discussing the role rapid prototyping techniques can play in the software lifecycle, the paper looks at possible technical approaches including: heavily parameterized models, reusable software, rapid prototyping languages, prefabrication techniques for system generation, and reconfigurable test harnesses.The paper concludes that a multi-faceted approach to rapid prototyping techniques is needed if we are to address a broad range of applications successfully -- no single technical approach suffices for all potentially desirable applications

Build Time Estimations for Large Scale Modelling

Achieving speedy results in model making is very much desired if not a necessity in ahnost any manufacturing industry. There is no doubt that rapid prototyping contributes to this process. It is generally considered that when compared to conventional machining techniques like nlilling, the current rapid prototyping systems appear to be much faster. This is certainly true for complex,slnall objects. I-Iowever, this is not alwaysa,pplicable to simple, large and bulky parts. There are a number of projects and systems concentrating on the fabrication of large models. Work is being carried out at the University ofHong Kong, using milling. along with slicing technology. This.report compares some ofthe rapid prototyping systems witl1milling. Milling is an established technology and recent developments in materials and nlachines used in Inilling nlake it a good alternative to rapid prototyping when itcomes to largesyale nl0delling.Mechanical Engineerin

Optimisation of Subtractive Rapid Prototyping Process Parameters using Response Surface Methodology

Subtractive rapid prototyping machine is the most suitable tool to manufacture a polymer based prosthetic part because it is able to achieve a low surface roughness value for a complex and customised part. Many investigations have been conducted to explain the relation among the surface roughness value, the material rate removal, and the subtractive rapid prototyping process parameters. It is important to find the optimum process parameters in order to achieve the most efficient and productive process. However, none of the research found in the literature optimises the subtractive rapid prototyping process parameters in fabricating polycarbonate part. Therefore, this research goal is to find the optimum process parameters to achieve the lowest arithmetic average of surface roughness value of the polycarbonate part in maximum material removal rate. In this research, the response surface methodology is implemented to optimised feed rate, step-over, and depth of cut of the subtractive rapid prototyping process. This research finds the feed rate, step-over, and depth of cut values that can be used to achieve the best result in manufacturing of polycarbonate material

Virtual assembly rapid prototyping of near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel non-layered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper

Virtual bloXing - assembly rapid prototyping for near net shapes

Virtual reality (VR) provides another dimension to many engineering applications. Its immersive and interactive nature allows an intuitive approach to study both cognitive activities and performance evaluation. Market competitiveness means having products meet form, fit and function quickly. Rapid Prototyping and Manufacturing (RP&M) technologies are increasingly being applied to produce functional prototypes and the direct manufacturing of small components. Despite its flexibility, these systems have common drawbacks such as slow build rates, a limited number of build axes (typically one) and the need for post processing. This paper presents a Virtual Assembly Rapid Prototyping (VARP) project which involves evaluating cognitive activities in assembly tasks based on the adoption of immersive virtual reality along with a novel nonlayered rapid prototyping for near net shape (NNS) manufacturing of components. It is envisaged that this integrated project will facilitate a better understanding of design for manufacture and assembly by utilising equivalent scale digital and physical prototyping in one rapid prototyping system. The state of the art of the VARP project is also presented in this paper