Abstract
In this work, two complex-shaped products have been reverse engineered through rapid prototyping (RP). First product is a single unit with a number of complex features while the second product has sub-parts to be assembled together. These sub-parts have various complexities. One sub-part will frequently be in motion. Target points are set on complex features of the scanned 3D point data to measure deviations of generated surface models from scanned data and subsequently from physical models. Two layer-by-layer manufacturing systems, i.e. one employing ceramic powder-based 3D printing and other fused deposition method have been used to develop RP models of complex shapes. Suitability of the process for complex-shaped prototypes has been discussed and recommendations have been made for parameter settings and suitable process. Moreover, economic analysis has also been performed with an objective to minimize the development time and cost.
Similar content being viewed by others
References
Hosni YA, Harrysson OLA (2002) Design and manufacturing of customized implants. IERC 2002, Orlando, Florida, USA, May 19–21
Zhang Y, Liu H (2009) Application of rapid prototyping technology in die making of diesel engine. Tsinghua Sci Technol 21/38, 14(S1):127–131
Al Mardini M, Ercoli C, Graser GN (2005) A technique to produce a mirror-image wax pattern of an ear using rapid prototyping technology. J Prosthet Dent 94(2):195–198
Lohfeld JS, McHugh P, Serban D, Boyle D, O’ Donnell G, Peckitt N (2007) Engineering assisted surgery: a route for digital design and manufacturing of customized maxillofacial implants. J Mater Process Tech 183:333–338
Pham DT, Gault RS (1998) A comparison of rapid prototyping technologies. Int J Mach Tool Manuf 38:1257–1287
Yan Y, Li S, Zhang R, Lin F, Wu R, Lu Q, Xiong Z, Wang X (2009) Rapid prototyping and manufacturing technology: principle, representative technics, applications, and development trends. Tsinghua Sci Technol 01/38, 14(S1):1–12
Olszewski R (2013) Three-dimensional rapid prototyping models in cranio-maxillofacial surgery: systematic review and new clinical applications. In: Proceedings of the Belgian Royal Academies of Medicine
Chua CK, Hong KH, Ho SL (1999) Rapid tooling technology. Part 1. A comparative study. Int J Adv Manuf Technol 15:604–608
Horváth I, Yang D-Y (2002) Rapid technologies: solutions for today and tomorrow. Comput Aided Des 34:679–682
Ibrahim D, Broilo TL, Heitz C, De Oliveira MG, De Oliveira HW, Nobre SM, Dos Santos Filho JH, Silva DN (2009) Dimensional error of selective laser sintering, three-dimensional printing and PolyJet models in the reproduction of mandibular anatomy. J Craniomaxillofac Surg 37:167–173
Safira LC, Bastos LC, Beal VE, de Azevedo RA, Francischone CE, Sarmento VA (2013) Accuracy of rapid prototyping biomodels plotted by three dimensional printing technique: ex vivo study. Adv Comput Tomogr 2:41–45
Bill JS, Reuther JF, Dittmann W, Kübler N, Meir JL, Pistner H, Wittenberg G (1995) Stereolithography in oral and maxillofacial operation planning. Int J Oral Maxillofac Surg 24:98–103
D’Urso PS, Atkinson RL, Lanigan MW, Earwaker WJ, Bruce IJ, Holmes A, Barker TM, Effeney DJ, Thompson RG (1998) Stereolithographic (SL) biomodelling in craniofacial surgery. Br J Plast Surg 51:522–530
D’Urso PS, Earwaker WJ, Barker TM, Redmond MJ, Thompson RG, Effeney DJ, Tomlinson FH (2000) Custom cranioplasty using stereolithography and acrylic. Br J Plast Surg 53:200–204
Silva DN, Gerhardt de Oliveira M, Meurer E, Meurer MI, Lopes da Silva JV, Santa-Bárbara A (2008) Dimensional error in selective laser sintering and 3D-printing of models for craniomaxillary anatomy reconstruction. J Craniomaxillofac Surg 36:443–449
Choi JY, Choi JH, Kim NK, Kim Y, Lee JK, Kim MK, Lee JH, Kim MJ (2002) Analysis of errors in medical rapid prototyping models. Int J Oral Maxillofac Surg 31(1):23–32
Nizam A, Gopal RN, Naing L, Hakim AB, Samsudin AR (2006) Dimensional accuracy of the skull models produced by rapid prototyping technology using stereolithography apparatus. Arch Orofac Sci 1:60–66
Cohen A, Laviv A, Berman P, Nashef R, Abu-Tair J (2009) Mandibular reconstruction using stereolithographic 3-dimensional printing modeling technology. Oral Surg Oral Med Oral Pathol Oral Radiol Endodontol 108(5):661–666
Subburaj K, Nair C (2007) Rapid development of auricular prosthesis using CAD and rapid prototyping technologies. J Oral Maxillofac Surg Med 36:938–943
Noy L (2005) An investigation of the performance of low cost rapid prototyping machines. M.Sc. Thesis, DE Montfort University. Available on. http://www.Google.com
Childs THC, Juster NP (1994) Linear and geometric accuracies from layer manufacturing. CIRP Ann 43(1):163–166
Jacobs PF (1992) Rapid prototyping and manufacturing: fundamentals of stereolithography. Soc Manuf Eng 1992:32–52
Ma’aram A, Sharif S, Zakaria K, Mohamed J (2003) Quality assessment of hollow prototypes model in fused deposition modelling. Master thesis, Universiti Teknologi Malaysia
Hayat N, Ashraf R, Javed O, Zulfiqar Z (2009) Reverse engineering of doll’s head using 3D laser scanning, printing and rapid prototyping. Under graduate project Department of Industrial and Manufacturing Engineering, UET, Lahore
Hayat N, Adrees A, Sipra SN, Umer Farooq M (2009) Reverse engineering of ergonomically designed mouse and design of its Virtual mold. Under graduate project Department of Industrial and Manufacturing Engineering, UET, Lahore
Hayat N et al (2011) Rapid product development: a case study of ergonomically designed mouse. Pak J Sci 63(2):32–48
Rapid prototyping lab, UET, Lahore. www.uet.edu.pk
Taylor-Hobson Surtronic S 25 operational manual
Acknowledgments
The authors acknowledge the support of Department of Industrial and Manufacturing Engineering, UET Lahore in carrying out the experimental work.
Author information
Authors and Affiliations
Corresponding author
Additional information
Technical Editor: Fernando Antonio Forcellini.
Rights and permissions
About this article
Cite this article
Ahmad, M., Hayat, N. & Shah, F.H. Rapid development of complex shaped customized products. J Braz. Soc. Mech. Sci. Eng. 37, 263–274 (2015). https://doi.org/10.1007/s40430-014-0185-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40430-014-0185-4