Rapid Prototyping : An Effective Tool for Manufacturing of Intricate Geometries of Automotive Components : A Case Study

Abstract

Tooling is one of the most important elements in the manufacturing process. To achieve the high quality requirements, moulds are traditionally made by CNC-machining, electro-discharge machining or conventional technologies. The term Rapid Prototyping (RP) refers to a group of technologies that can automatically construct physical model from Computer Aided Design data. Rapid Prototyping allows them to be made quicker and less expensively. The Rapid Prototyping techniques involves basic five step process like, Create a 3D CAD model of the required design, Convert the CAD model to STL format, Slice the STL file, Construct the model Layer by Layer and finally Clean and finish the model. Rapid Prototyping is widely used in fabrication of intricate parts of automotive, aerospace, medical and consumer products industries. Also especially moulds are made from RP model from Rapid Tooling. In this paper, a case study of manufacturing of engine head is taken. In contrast to construction of models by machining, based on the removal of material until the required form is achieved, RP model is made by adding material layer by layer until the whole part will be completed.