"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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