How To Design A 3D Model For A 3D Printer

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R

APID

P

ROTOTYPING

S

ERVICE MODEL

BY THE

CDIO

*)

EDUCATIONAL

Poznan 11. – 12.10.2010

BY THE

CDIO

*)

EDUCATIONAL

FRAMEWORK

*)

C

_onceive

D

_esign

I

_mplement

O

_perate

Lauri Tenhunen Seppo Aarnio

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RPS

CDIO

PROCESSES OF

INNOVATION

INDUSTRY

RPS

RP-TECHNIQUES

ELEMENTS OF RPS MODEL

(Rapid Prototyping Service Model)

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WHAT IS CDIO ?

CDIO

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CDIO

AN INNOVATIVE EDUCATIONAL

PROGRAM FOR PRODUCING THE

NEXT GENERATION OF ENGINEERING

LEADERS.

IT FORMS THE BASIS OF YOUNG

UNDERGRATUATE EDUCATION.

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REAL-WORLD DEMANDS REAL-WORLD DEMANDS REAL-WORLD DEMANDS ENGINEERING EDUCATION ENGINEERING EDUCATION ENGINEERING

EDUCATION

CDIO

DEMANDSDEMANDSDEMANDS EDUCATION

EDUCATION

CDIO

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”Graduating engineers should be able to

C

onceive-

D

esign-

I

mplement-

O

perate

complex value-added engineering systems

in a modern team-based environment.”

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Knowledge of Underlying Sciences Core Engineering Teamwork Communication Communication in Foreign Languages

Fig.1 CDIO Blocks of knowledge

Core Engineering Fundamentals

Advanced Engineering

Fundamentals Engineering Reasoning and Problem Solving

Experimentation and Knowledge Discovery System Thinking

Personal Skills and Attitudes

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ESC

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BENEFITS OF CDIO

• Fresh ideas

• Increased cooperation

• Theory into praxis

• Students will learn the laws and language of

business world

• Working together in teams with different people

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PRODUCT INNOVATIONS IN

INNOVATION

PROCESSES OF

INDUSTRY

PRODUCT INNOVATIONS IN

ENTERPRISES

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PRODUCT DEVELOPMENT CONSISTS OF SEVERAL STEPS

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RAPID PROTOTYPING PERFORMANCE

RP-TECHNIQUES

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FUNDAMENTAL FABRICATION PROCESSES

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C K Chua, K F Leong, & C S Lim: Rapid Prototyping: Principles and Applications

AM

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Additive manufacturing (AM)

is defined by ASTM as the process of

joining materials to make objects from

3D model data, usually layer upon

layer.

RP is one form of AM. It is used in making

prototypes

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All RP techniques basically follow the same 5-step

system:

1. Creating a 3D CAD model of the design

2. Converting the CAD model to STL format

3. Slicing the STL file into thin cross-sectional layers

4. Constructing the model one layer atop another

5. Cleaning and finishing the Model

To prototype successfully you need to select an

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CAD MODEL CREATION:

• using a CAD software package

• or by using a laser scanner or a Coordinate

Measuring

Machine (CMM). (”Reverse

engineering””)

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CONVERSION TO STL FORMAT:

The standard data interface between CAD sofware and the

machine is the STL-format (Stereolithography).

An STL-file approximates the shape of a part using triangular

facets. Small facets produce a high quality surface.

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Since the .stl format is universal, this process is identical

for all of the RP build techniques.

SLICING THE STL FILE:

The program may also generate an auxiliary structure to

Support the model during the build

http://www.youtube.com/watch?v=80aXU5q2Kgg

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LAYER BY LAYER CONSTRUCTION:

The fourth step is the actual construction of the part.

Using one of several techniques (described later) RP

machines build the model layer by layer.

The material´s initial states are:

• LIQUID

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• LIQUID

• SOLID or

• POWDER

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• Practically no limitations to the form to be produced.

• Reduction in time and cost (could range 50 – 90%. Wohler)

• Errors and flaws can be detected at an early stage.

• RP/RM can be used in different industries and fields of life

(medicine, art and architecture, marketing..)

• Discussions with the customer can start at an early stage.

• Assemblies can be made directly in one go.

• Material waste is reduced.

GENERAL ADVANTAGES OF RP

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• Material waste is reduced.

• No tooling is necessary.

• The designers and the machinery can be in separate places.

•

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APPLICATIONS OF AM

Technology

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The task was to test different alternative INTAKE MANIFOLDS. The

19/10/2010 S.AARNIO

The task was to test different alternative INTAKE MANIFOLDS. The parts (three) were made of Windform XT with laser sintering. By using SLS the time from desktop to product took only about 10 % of the time earlier.

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Medicine

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Models of skulls etc can be used for training of surgical operations

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These siamese twins were succesfully separated. The operation was planned with models of the skulls.

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Architecture

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RP/AM-TECHNOLOGIES

• Stereolithography (SLA)

• Fused Deposition Modeling (FDM)

• Selective Laser Sintering (SLS)

• Laminated Object Manufacturing (LOM)

• 3D Printing

• Direct metal laser sintering (DMLS)

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SLA

STEREOLITHOGRAPHY

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FDM

FUSED DEPOSITION MODELING

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SLS

SELECTIVE LASER SINTERING

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LOM

LAMINATED OBJECT MANUFACTURING

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RPS BY THE CDIO FRAMEWORK

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To formulate the RPS model logically, we will

first arrange the needed elements into groups

of

objects (nouns)

and

actions (verbs)

and

of

objects (nouns)

and

actions (verbs)

and

then describe the three processes

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THE LIST OF OBJECTS (NOUNS) WILL

INCLUDE FOLLOWING:

• The RP team (including students

and experts)

• The customer and its agents

• The target product and its

properties

• The RP technique chosen

• The Prototype

• The time schedule and the

budget

THE LIST OF ACTIONS (VERBS) WILL

INCLUDE FOLLOWING:

• Discussing the task and choosing the innovation level

• Regulating and adjusting the RP process during work

• Changing, Developing and Iterating the Prototype

• Testing the prototype solutions • Finishing the best prototype

• Saving the necessary CAD documents • Consulting and Advising by experts

• The time schedule and the

budget

• Consulting and Advising by experts

• Learning to conceive, design,

implement and operate the RP process by the students

• Making decisions by the customers

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3.

I

mplementing 4.

O

perating Final Prototype Evaluation Learning outcomes Penetration Decisions Marketing, Production Test marketing Commercial iterations Product development FIGURE:

RPS in relation to CDIO Engineering Education and Enterprise product development function

D

esigning 2.

C

onceiving 1. _{Project idea} conception Prototype Product Design Evalution Planning

Planning with CAD RP modelling

Technical iterations _{Requirement Analysis}Product conception

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The students involved in the RPS process

are able to adopt the

• techniques of RP engineering

and also

• fundamentals of engineering service

processes

and

• business to business service sales.

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RP team

, proper for CDIO education

framework within a university, would

include:

• competent teacher(s),

• group of students,

• programmer(s),

• enterprise representatives.

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Enterprise Actions Assignment Idea Conception Team Actions Participation Evaluation Product targets Learning targets Fig. 6

RPS Model and Actions. The model includes four elements: The team, the system, the product and the enterprise

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Enterprise Actions Assignment Requirements Idea Conception Team Actions Participation Evaluation Product targets Learning targets Planning CAD models Mentoring CAD modelling Evaluation

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Enterprise Actions Assignment Requirements RP modelling Iterations Evaluation Planning Feedback Idea Conception Planning CAD models Team Actions Participation Evaluation Product targets Learning targets Mentoring CAD modelling Evaluation

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RP modelling Iterations Enterprise Actions Assignment Requirements Evaluation Planning Feedback Testing: Technical and commercial Proposal Final Prototype Idea Conception Planning CAD models Team Actions Participation Evaluation Product targets Learning targets Mentoring CAD modelling Evaluation

Developing physical models

Proposal Approval Modifications

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RP modelling Iterations Enterprise Actions Assignment Requirements Evaluation Planning Feedback Testing: Technical and commercial Proposal Final Prototype Testing Decisions Final Product Evaluation Learning outcomes Idea Conception Planning CAD models Team Actions Participation Evaluation Product targets Learning targets Mentoring CAD modelling Evaluation