"User's Guide to Rapid Prototyping"
Table of Contents

Preface
Acknowledgement
Dedication
Chapter 1: Introduction to Rapid Prototyping
- Creating Understanding and Awareness
- What is Rapid Prototyping?
- Detailed Technology Description
- Shades of Gray
- A Tool for Change
- Informed Decisions
Chapter 2 - Overview of Rapid Prototyping
- Definition of Rapid Prototyping
- History of Rapid Prototyping
- Timeline
- Why Prototype?
- Overview of Rapid Prototyping Benefits
- Overview of Rapid Prototyping Applications
- Product Development
- Other Disciplines
- Types of Rapid Prototyping Systems
- 3D printers:
- Enterprise Prototyping Centers
- Direct Digital Tooling
- Direct Digital Manufacturing
- Overview of Rapid Tooling and Rapid Manufacturing
- Rapid Tooling
- Rapid Manufacturing
- Future of Rapid Prototyping
Chapter 3 -The Rapid Prototyping Process
- Process Overview
- Process Detail
- STL File Generation
- CAD
- STL File Creation
- File Verification and Repair
- Build File Creation
- Part Orientation
- Support structures
- Part Placement
- Slicing
- Build File Creation
- Part Construction
- Part Cleaning and Finishing
- Cleaning
- Finishing
- Conclusion
- Process Strengths and Limitations
- Strengths
- Limitations
- Strength, Weakness or Opportunity?
Chapter 4 - Classes of Rapid Prototyping Systems
- 3D printers
- Enterprise Prototyping Centers
- Direct Digital Tooling
- Direct Digital Manufacturing
- System classification
- Stereolithography
- Selective Laser Sintering
- Fused Deposition Modeling
- Powder-Binder Printing
- Specialization Replaces General-Purpose
Chapter 5 - Applications and Benefits of Rapid Prototyping
- Applications
- Design
- Concept models
- Form and fit checking
- Ergonomic studies
- Functional testing
- Requesting price quotes
- Proposals and presentations
- CAD data verification
- Design for manufacturing analysis
- Patterns
- Beyond Design Engineering
- Rapid Tooling
- Rapid Manufacturing
- Beyond Design and Manufacturing
- Science and Medicine
- Building Construction and Architecture
- Archeology, Paleontology and Forensic Science:
- Miniaturization
- Benefits of Rapid Prototyping
- Time
- Cost
- Quality
- Capability
- For the Individual
- Conclusion
Chapter 6 -Comparing Rapid Prototyping to CNC Machining
- Pragmatic Decisions
- Process Comparison
- Output Quality
- Materials
- Maximum part size
- Part Complexity
- Feature Detail
- Dimensional Accuracy
- Repeatability
- Surface finish
- Operations
- Staffing
- Skilled labor
- Reliability
- Time
- Construction Time
- Pre-processing Time
- Post-processing Time
- Total Lead Time
- Cost
- Summary
Chapter 7 -Rapid Prototyping System Review
- Systems Reviewed
- Process Overview
- Stereolithography
- Selective Laser Sintering
- Fused Deposition Modeling
- Powder-Binder Printing
- Process Detail
- Stereolithography
- Selective Laser Sintering
- Fused Deposition Modeling
- Powder-Binder Printing
- Comparison - Prototype Properties
- Material Properties
- Color
- Dimensional Accuracy
- Stability
- Surface Finish
- Feature Definition
- Machinability
- Environmental Resistance
- Physical Size
- Comparison - Operational Properties
- Time
- Support Structures
- Post-Build Processing
- Comparison - Prototype Applications
- Concept Models
- Form, Fit and Function Models
- Patterns
- Rapid Tooling
- Rapid Manufacturing
- Conclusion
Chapter 8 - Developing a Justification for Rapid Prototyping
- In-house and Service bureaus
- Economic Justification
- Strategies for Justification
- Hidden Costs
- System Expense
- Facility Improvements
- Staffing
- Material Costs
- Supporting Equipment
- Maintenance
- Cleaning and Finishing
- Miscellaneous
- Additional Considerations
Chapter 9: Evaluation and Implementation
- The Challenge
- Defining Realistic Needs
- Evaluating Rapid Prototyping Systems
- Materials
- Properties
- Speed
- Cost
- Safety and environmental
- Other Considerations
- Systems
- Physical properties
- Operational Criteria
- Implementation
- A Champion Technology Implementation:
- Front-End Systems
- Rapid Prototyping Systems
- Back-End Operations
- Conclusion
Chapter 10 - Rapid Tooling and Rapid Manufacturing
- Definition of Rapid Tooling and Manufacturing
- Years of Effort, Limited Use
- Rapid Tooling
- Indirect Processes
- Limitations of Indirect Processes
- Direct Processes
- Limitations of Direct Processes
- Rapid Tooling Future Developments
- Rapid Manufacturing
- Rapid Manufacturing Technologies
- Rapid Manufacturing Limitations
- Benefits of Rapid Manufacturing
Chapter 11 - Moving Forward
- Introduction
- Barriers to Growth
- CAD
- Better Materials
- Improved Output
- Easier to Use
- Lower Cost
- Future Developments
- Standardization
- Specialization
- 3D Printing and Rapid Manufacturing
- 3D Printing
- Rapid Manufacturing
- Conclusion
Case Studies - Appendix A
- Rapid Prototyping Promotes More Design Iterations, Smoother Pilot Test
- Snowshoe Design Hits the Fast Track
- Finite Element Analysis Results Printed in 3D
- Ancient Greek Statue Reproduced with Rapid Prototyping
- Technology and Innovation Used to Boost Aging Product
- Process Comparison: Stereolithography and RTV Molding
- Rapid Prototyping Assists Surgeons Planning Separation of Conjoined Twins
- Rapid Tooling Cuts Processing Time By 50% to 75%
- Rapid Prototyping Credited for Multi-Million Dollar Contract
- 3D Printer Applied to Functional Testing and Rapid Manufacturing
- Chevy SSR Relies on Rapid prototyping
- Big Rigs Benefit from Rapid Prototyping
- BioMolecular Models for Research and Education
- Ski Binding Innovation Fueled by Rapid Prototyping
- PRO Series Power Fastening Tool Perfected with Rapid Prototyping
Rapid Prototyping Resources - Appendix B
- Contributors
- Manufacturers
- Equipment
- Materials
- Repair, Parts, Service
- Software
- Consulting & Training
- Publications
- Books
- Periodicals & Journals
- Events
- Information
- Web Sites
- Forums and Mail Lists
- Associations
- Research and Education
Rapid Prototyping Glossary - Appendix C
Contact information:
Todd Grimm
T. A. Grimm & Associates, Inc.
3028 Beth Court, Edgewood, Kentucky 41017
Phone: (859) 331-5340 Fax: (859) 514-9721
tgrimm@tagrimm.com www.tagrimm.com
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