Multi-axis Rapid Prototyping

Neil Sewell

Dr. Martin Jenkins & Dr. Richard Everson

Overview

What is RP, why use it, who uses it?

Previous work

Current work and Future work

Lab demonstration

Rapid Prototyping – 3 types Type 1 - DTM Laser sinterstation

Rapid Prototyping Type 2 - 3D Systems’

Stereolithography

Rapid Prototyping Type 3 - 3D Printers

RP – Why use it? Injection moulds are expensive to

produce

One-off test pieces can be used in real world

Great for real world ergonomic testing

RP – Who uses it?

Virtually all major device manufacturers

Designers & Prototypers

One-off producers

Previous work... SARP is Single Axis Rapid

Prototyping

SARP – Single Axis RP SARP is quick, cheap and easy.

Allows building of quite complex models

Is fast and efficient

But… Will not allow for large overhangs Is not to the same resolution

Examples of SARP Cubes

Spheres

Arches

Logos

Current work... MARP is Multi Axis Rapid Prototyping

Still uses VMC, Hot glue nozzle and glue

Different, more complex software

Add-on 4th and 5th Axis units to rotate models

MARP – Multi Axis RP

Models with overhangs could be built

Building direction is continuously changed

Models created would of better quality

The process would be quicker

How to MARP – Step 1

Perform analysis of object - create a usable data structure.

How to MARP – Step 2 Select start location & direction

How to MARP - Step 3 Start the edge following process

How to MARP – Step 4 Create machine instructions

Use glue path to locate x,y,z position

Use facet data to provide rotation values

Use collision detection methods!

(Lab demonstration at end of presentation)

Latest Work Uses many rules

Edge vector creation & analysis Unnecessary edge deletion & detection Improvement & Optimisation techniques

Current problems include Holes in model Sticky tight corners Finishing problems

Conclusion MARP work is going well - But is

difficult

Software Multiple data lists Edge following Uses Downhill Simplex Method Started testing Simulated Annealing

Conclusion Realism with MARP - What can it

build?

Difficult shapes

Disjoint shapes

Really complex shapes?

Thank you for listening…

Questions

Visit to lab for Multi-Axis demonstration