Rapid Prototyping - MIT

Rapid Prototyping & Alternative Manufacturing Techniques or how to get it done differently than we told you yesterday Outline

Welding Waterjet EDM Stereolithography & 3-D printing Casting Forming

Injection Molding Thermoforming Outline

Welding Waterjet EDM Stereolithography & 3-D printing Casting Forming Injection Molding

Thermoforming Welding Fabrication method that joins metal by melting the base materials & adding a filler Needs protective clothing, masks, special equipment STRONG welds take practice and experience, otherwise get a professional to do it

weld Base material Heat affected zone Waterjet Cut material using highpressure water and an abrasive powder

No Heat-Affected Zone Can cut almost anything No tempered glass, some ceramics Waterjet - DFM Planar geometry Kurf part wont have straight edges EDM Electrical Discharge

Machining Must be conductive material Great for cutting very hard material easily Expensive & hard to find shops that do it

Intricate detail Non-contact machining Stereolithography & 3-D Printing Go straight from CAD to part Material is often brittle, although new polymers are being developed Can have undercuts, long holes, high depth-width ratios

Stereolithography & 3-D Printing Sand Casting

Interesting part geometries Can be pretty cheap Not good surface finish Not good accuracy Need to make pattern Need draft angles Shrinks on cooling (not predictable) Local (Burlington, MA)

Forming Can bend or punch sheet metal Cheap, fast, easy Not very accurate Injection Molding Melt plastic pellets and presses melted plastic into molds Molds have to be machined, expensive,

time-intensive Good for high-rate production Thermoforming Thermoplastic heated to a rubbery consistency and then stretched over a mold and allowed to cool Not high precision or accuracy Good for moderately complex geometry

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