Rapid Development Presentation David Pollock

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Rapid DevelopmentRapid Development

David P PollockDavid P Pollock28 JUN 0628 JUN 06

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AgendaAgenda

• What is Rapid Prototyping (RP)? What is Rapid Prototyping (RP)? • Why use RPWhy use RP• RP TechnologiesRP Technologies• Integrating RP TechnologyIntegrating RP Technology• QuestionsQuestions

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What is Rapid What is Rapid Prototyping?Prototyping?What is Rapid What is Rapid Prototyping?Prototyping?

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Rapid prototypingRapid prototyping

• Communications tool• Additive or subtractive process• Growing parts introduced in 1987• Parts of any geometric complexity• Rapid tooling• VOC

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Rapid prototypingRapid prototyping

• Additive not intended to replace all methods of part fabrication

• Limited material choices - additive• Parts will not be as durable• May require extensive secondary finishing

operations

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Why use RP?Why use RP?Why use RP?Why use RP?

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Rapid prototypingRapid prototyping

• A six month delay in production start can result in a 66% loss in gm*

• 80% of costs of NPD before detailed drawings released*

• VOC – LEAN• Touch, feel, hold vs. 3D model

*Copyright © 2002-2006  T. A. Grimm & Associates, Inc. All rights reserved.   

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Rapid prototypingRapid prototyping• Easy• Efficient

– Concurrent engineering

• Accessible• Iterations

– Communicate ideas

– VOC

– Sales

– Packaging

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RP TechnologiesRP TechnologiesRP TechnologiesRP Technologies

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Additive Rapid PrototypingAdditive Rapid Prototyping

Build-up process• 3-D Printing• Fused Deposition Modeling• Stereolithography• Selective Laser Sintering• Jetted Photopolymer

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• Developed by MIT

• Powder-adhesive process

• Lowest cost technology

• Five times faster

• Limited materials

Rapid prototypingRapid prototyping

3-Dimensional Printing3-Dimensional Printing

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• Similar to 3-D printing

• Fast for very small parts

• Suitable for office use

• Polymer filament ribbon

• Engineered materials: ABS, PC, PPS

Fused Deposition Modeling - FDMFused Deposition Modeling - FDM

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• Most widely used process

• Largest part size

• High accuracy

• Good surface finish

• Liquid polymer – laser cured

• Part size up to

29” x 25” x 21”29” x 25” x 21”

Stereolithography - SLAStereolithography - SLA

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• Large part size

• High accuracy

• Post-forming operations

• Engineered resins – highest strength

• Autoclave capable

• Lower surface quality compared to SLA

Selective Laser Sintering - SLSSelective Laser Sintering - SLS

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• Similar to inkjet printing

• UV curable resin

• Lower cost than SLA

• Suitable for office use

• Thin build layer – little post build finishing

Jetted Photopolymer System - PolyJetJetted Photopolymer System - PolyJetTMTM

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Subtractive Rapid Prototyping - SRPSubtractive Rapid Prototyping - SRP

Material removal process• 4-axis high-speed mill

– Lower equipment cost

– Non-proprietary materials

– No post-finishing

– Bridge tooling

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Integrating RP Integrating RP TechnologyTechnology

Integrating RP Integrating RP TechnologyTechnology

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Rapid DevelopmentRapid Development

Innovation CenterInnovation Center• Experimental design facility• Manufacture one-off samples and small lot parts• Easy-to-use equipment eliminating need for machinist• Rapid prototyping equipment

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Rapid DevelopmentRapid Development

Partnership - Hybrid TechnologyPartnership - Hybrid Technology• Partner with capable supplier• Combine rapid machining with subtractive technology• Capacity exclusivity• Production level parts in production materials• Bridge tooling to manufacturing

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Special Thanks:Special Thanks:Special Thanks:Special Thanks:

Todd Grimm, TA Grimm & Associates

Photo Credits: Castle Island Co., All Rights Reserved.