Welcome friends, welcome to the course of Introduction to Rapid Manufacturing. This

course we will go through the topics given here.

So, Rapid Manufacturing is a word or is a coined word which is gaining lot of momentum

in the recent times. Today, when there is lot of requirement for customization and now

I have to rephrase this term also now today people talk about mass customization. For

example, I would like to have a spoon which could cater my requirement; I would like to

have a shoe which can cater my requirement. Please understand a shoe my requirement; a

spoon my requirement. I would like to have a camera which could fulfil my requirement.

I would like to have a car which could fulfil my requirement. See I have brought four examples

in front of you and I said all these things a spoon for me; a camera for me; a car for

me; a shoe for me. When I take the first example a spoon, when we look at spoons there is something

called as teaspoon and slightly you go up you have a spoon which is normally we use

it in parties and other things. Many a times these spoons are not customized for my requirement;

that means, to say for my hand and the other thing is the weight of the spoon.

So, because of that many a times I spill my food right the spoon what I have is not customized

for my requirement and when I talk about shoe all of all of us the population is boxed under

sizes like 6, 7, 8, 9 and 10, 11, 12 maybe this is in terms of Indian Standards. If you

go for or American Standards they talk about in terms of inches and sometimes they talk

about in terms of centimetres. We are boxed in each of the requirement.

When I buy a shoe of size number 10 or 11 for example, I only have the option of deciding

whether it is a party issue or a sport shoe. If there is a sport shoe, I just pick, then

I have what are the options left is the colour I have that is all. But when my friend also

goes he also is buying the same shoe what happens to my body to mass index, where is

it getting integrated with the shoe? If I have a size between 6 and 7 or 9 and 10, 9

and a half, then How is my shoe going to take care of it?

I do not have customisation, I accept what is available. Many a times when you buy shoe

and when you are trying to play games football, you can see some of the child children, When

they are kicking, their shoe the football the shoe just flies off. Because it did not

fix it properly to his foot. So, because of this what happens? He gets into knee problem

over a period of time. Then let us take at an example of camera. Almost all the cameras

which are available in the market today are for right handers. Many of the products which

are available in the market are for right handers.

If you are a left hander all you have to do is swap that button from the right hand side

to the left hand side. So, we do not have that customization. Today there is a statistics

which says about 8 percent of the total world population are left handers. when the chairs

are made for the examination, we always try to make it more friendly towards the right

hander and not towards the left. So, here again the problem of customization is not

coming into effect. The last one let us try to look at a car which

is available in the market which is prepared or done for assuming a standard height for

a driver let it be male or female. When there is a small variation in your height, weight

or in your body to mass index or your shape of the body, there is no provision in the

car to customize it such that you can have a comfortable journey for a longer time and

you also have a complete view both in your right hand side and left hand side. So, now,

I have put in front of you four examples the first one was very low cost, next one was

slightly higher. Today you have shoes for 1000, 2000 and 5000 rupees or 10000 rupees.

Then I gave you an example of a camera and the last one I give an example of a car. We

are paying a huge money for all these products, but these products are not customized to my

requirement. So, now, there comes a challenge, What is the challenge? Why is it not done

why is it not done? Because the users are not captured and then the product is not made.

So, now, comes a relook into your definition we are not supposed to produce more in terms

of batches, but produce less, but make it more mass customized.

This is what is going to be the future manufacturing; future manufacturing is going to be more towards

mass customization. When we talk about mass customization we cannot sacrifice time, we

cannot sacrifice cost. So, we are still supposed to work to the expectation of the customer

both in terms of economy and in terms of time delivery. So, in this scenario we are pushed

from mass production to batch production to mass customised production. So, this mass

customised production is termed or is redrafted and given a terminology called as Rapid Manufacturing

What is Rapid Manufacturing? We try to take the customer feedback or requirements converted

it into a digital form; and that digital form is given directly to the machine the parts

are produced and directly moved towards an application. So, we are not going to go into

a field called as prototyping, we make a prototype for that prototype then we make tools and

from that tools we try to go for the final product. So, Rapid Manufacturing is more towards

mass customization where cost is not to be compromised, but things have to be produced

to the customers satisfaction with the highest integrity, that is Rapid Manufacturing.

For this topic we and we are supposed to go through rapid prototyping and we will see

reverse engineering some termino some technologies and Rapid Manufacturing we will see in totality.

So, this course is a futuristic course it is open for undergraduates and postgraduates

practicing engineers can also enjoy this course. So, along with me in this course I have Amandeep

Singh, who will share the lectures with me and we hope that we try to make an impact

and add a new knowledge to your understanding. So, I would now try to tell you an example

which we are recently working at IIT Kanpur. We had a patient who came to us and said that

he has lost his ear in an accident. All he wants to do is, because of this losing of

his ear in an accident he has stopped moving outside world. So, he has got himself confined

within a space and now he realized that that is not the future. So, he came down to us

at IIT Kanpur and he said can you make another ear for me of course, it involves lot of medical

involvement, but all we agreed to him is that ok let me let us try working along with a

partner with some doctor practicing doctor and we will try to do the engineering requirements.

So, we worked with him. So, what we did was we copied his left ear and he has lost his

right ear, we copied his left ear and We did Reverse Engineering then we developed it by

cad model, then we did some patch work here and there and then what we did was, we tried

to make a prototype of it then we try to make a mould out of it and from that mould we made

a final component and then we have today given it to him and said that please use this ear.

So, it is made out of silicon it gives it has the same flexibility and we have also

tried to do justice for the texture and now with the help of the doctors what we have

done is, we have also allowed him to just keep at his the location of the ear; from

a very far off distance it looks like he has a true ear.

So, this could happen only because of Rapid Manufacturing and the involvement of Additive

Manufacturing. So, this is what we are trying to cover in this course. The example I have

told you we are still working on it, it has to be placed we are trying to apply some magnets

this and that. So, there is a long way to go, but partially we have addressed the problem

and we are able to help him at least now the patient is able to fix his ears at the location

and then keep going. It has it is not been integrated as part of his body, but he just

keeps it as an insert to his body. So, this is Rapid Manufacturing ok.

So, in this lecture 1, we will try to see Additive Manufacturing we would see a rapid

prototyping then we will see functional prototyping then we will see Rapid Manufacturing then

rapid tooling and finally, direct and indirect manufacturing.

When we talk about Rapid Manufacturing the industrial 3D printer is at the tipping point,

about to go mainstream in a big way. So, earlier Additive Manufacturing was thought of only

from the prototyping point of view, today What has happened? The power source whatever

you apply, the raw material whatever we use are now moving towards the real-time requirements,

which was earlier thought about in plastic now it is changed into metal.

So, earlier we used to make only polymer based prototyping, today we are making metal based

prototyping moment we make a prototype we are now pushing it little bit more to a live

requirement itself. So, that is why industrial 3D printing is at the tipping point about

to go mainstream in a big way. Main most executives and many engineers do not realize it, but

this technology has moved well beyond prototyping, rapid tooling and toys. Rapid Manufacturing

is creating durable and safe products for sale to real customers in moderate to large

quantities ok. So, this is where the terminology mass customization I talked about is getting

integrated. So, Rapid Manufacturing is creating durable and safe products for sale to real

customers in moderate, this moderate can be 1 to 10, 200, 500 whatever it is in moderate

to large quantities ok.

Today the major challenge is shrinking product manufacturing time. Earlier we used to talk

about, for if a company decides to make a car if a big giant company decides to make

a car, they say we will in the next 5 years we will come out with a new car, next 10 years

we will come out with a new car, but today it has come down to next 6 months we will

come out with a new car. So, What has happened? The product life cycle time has shrunk down;

the manufacturing time has shrunk down drastically ok. The assembly line processes revolutionized

production and dropped the assembly time for a single vehicle from 12 hours to few minutes.

Today we talk about product delivery in minutes. We talk about pizza getting delivered at our

residence in 30 minutes. So, look at the amount of readiness which this product has in these

stores. So, here the product is all in semi cook state or in a very raw state, then it

is all getting assembled it is passed through an assembly line where it is in terms of pizza

it is a furnace. So, it is passed through the oven, and then you get out after 10 minutes

or 20 minutes or 3 minutes you get a pizza right. So, now, they are talking about doing

product delivering products in 30 minutes. Today we are not talking about product production,

we are talking about product delivery. I produce and keep it in a warehouse does not matter

because the customer is not happy, if I produce and deliver it to a customer he is very happy.

So, today the manufacturing industry is working towards delivery that is produce or make to

delivery rather than make to produce and keep it in a stores.

Ford freeform fabrication technology or F 3 T will lower cost and speed the delivery

time for prototype stamping moulds, where in 3 business days versus just against 6 months

of prototyping may be used in the conventional machine. Since we are moving from Rapid Prototyping

to Rapid Manufacturing in between tooling segment is now slowly thought of why do not

we withdraw. So, here it is very clear within 3 business days 3 business days 3 working

days they are able to make a mould which earlier took them 6 months. So, what is this all talking

about? This is all talking about how quickly I can change my product, produce a product,

and try to customize the product to their requirement.

Through fords virtual factory, the company can improve quality and cut cost in real world

manufacturing facilities by creating and analyzing computer simulations of the complete vehicle

production process. Today we have virtual labs we have we call it as smart factories

or virtual factories we are able to simulate every condition which is there in real time.

See where the bottlenecks are understand where the product is going to fail by our simulation

try to reinforce the product wherever it is required and correspondingly try to change

the manufacturing route, assembly route and produce the part whatever we want.

So, this virtual factory is also part of Rapid Manufacturing. So, you can see here the ford

example which was earlier you have a person trying to handle where there is not much of

conveyor from there it is changed to a way where in which there is a fixture, there is

a conveyor fixture, there is a conveyor which moves from place to place and here is your

product ok. So, the product moves and since it is an assembly

line and it is continuously moving the assembly happening workstation, the time is also the

cycle time is also fixed. It is also fixed the cycle time is fixed the product is produced

the conveyor belt is moving and this is a fixture to hold it. Earlier the vehicle was

moving where there was man involved, but it had the cycle time was large, but now it has

shrunk down drastically.

U S Hearing Aid Company converted to 100 percent 3D printing in less than 500 day. So, today

hearing aids are made by Rapid Manufacturing. Today many products which are made for human

centric or human friendly they are all done digitized for example, they are first scanned

what is the requirement, converted into a digital form, the product is made such that

it can get adhered fixed in the required space. Aurora Flight Signs can print the entire body

of your drone in one build. Today people have also realized that if you want to make a 3D

product it is good we start making a 2D one and 2D one it is very quickly you can cut

through laser or any engraving tool you cut it and then you break the 2D things assemble

it you get the 3D part ok. So, aurora flight science can print the entire body of a drone

in one build. Local motors can print a good looking roadster from bottom to top in 48

hours. So, these are all some of the products which have been made under Rapid Manufacturing.

When we talk about Rapid Manufacturing in terms of units and cost, the price of Additive

Manufacturing is dropping in terms of technology awareness raw material cost third party involvement

in supplying the machine parts. So, the price of Additive Manufacturing is dropping, making

Additive Manufacturing increasingly competitive with conventional manufacturing due to the

difference in fixed cost versus variable cost. So, this is the conventional cost, this is

the Additive Manufacturing. So, you can see here the cost is drooping down at one point

where the breakeven is there. So, you can see if we are able to produce so much in quantity,

the cost then Additive Manufacturing will be economical as compared to that of your

conventional machine ok. So, this shows the higher cost, lower cost,

the cost per unit manufacturing and here it says unit manufacturing in terms of volume

ok. Of course, when more the volumes are there conventional is the best method of making

it. So, conventional methods are the best and especially sheet metal or metal forming

operations are the best it nothing can be economical than that. But, if the quantities

are literal you cannot use the same metal forming techniques here because the die cost

is pretty expensive ok. So, this is what is the breaking point, where in which tries to

talk about Additive Manufacturing and conventional cost in terms of units.

So, the future of Rapid Manufacturing when we talk about automotive; total automotive

Additive Manufacturing market which is projected for from 2017 to 2028 in terms of millions,

you can see here these are polymer parts, polymer prototype, polymer material you can

see polymer tools, metal prototyping you can also see metal tools and metal hardwares.

So, you can see them how drastically their numbers are getting increased over the years

you see this it is increasing. And if you see polymer material this is also increasing

ok. So, this is a very interesting graph which talks about what will be the future of Rapid

Manufacturing.

Let us see the Rapid Manufacturing status ok. So, I would like to draw block diagrams

this is Additive Manufacturing, this is rapid prototyping and this is Rapid Manufacturing.

This in turn, this is solid imaging and concept modelling and the next one is functional prototype

we will see what is functional prototype little later. I am just giving you the overview how

does it go about. We have prototyping tools then we have direct tools I have direct manufacturing

ok. So, I will divide it into segments, this is called as this is called as technology,

this is called as this is called as prototyping and this is called as manufacturing and I

will again divide this. So, that it becomes easy for understanding. So, this portion is

Additive Manufacturing additive processes and here we have non additive processes ok.

So, this from here I would like to go for indirect prototyping and then we have indirect

tooling and then we have indirect manufacturing ok. This is the current Rapid Manufacturing

status and if you look at it this is where technology, prototyping and manufacturing

is there. We have Additive Manufacturing, then we have rapid prototyping, then we have

Rapid Manufacturing ok. So, these are the arrows. So, we will try to see what is a Rapid

Manufacturing as and when the course goes by.

So, the major modules which we are going to cover in this is going to be introduction

to Rapid Manufacturing, then we will talk about product engineering

we will talk little bit about CAD which is Computer Aided Design slash CAE which is Computer

Aided Engineering then we will study about CAM, CAM Computer Aided Manufacturing and

Computer Integrated Manufacturing. CAD is only the drawing, a drawing with simulation

and optimization is CAE and which when it gets transferred for manufacturing it is called

a CAM and CAM with the office automation in an industry is called as Computer Integrated

Manufacturing. Then we will try to see design for modularity, this modular design makes

the manufacturing today more comfortable and easy for Rapid Manufacturing. We will talk

about reverse engineering we will talk about Rapid Manufacturing processes and technology,

then we will talk about Rapid Manufacturing digital factories.

We will also talk finally, about competitiveness in Rapid Manufacturing. This course is reinforced

with lab demonstration self-completion tasks, reading material and weekly quiz and many

of the quizzes will be for your understanding and some quizzes can be for you for submission.

And I will try to give you an exercise just from the live examples which you can think

of and start solving that assignment. You do not have to submit it for correction or

evaluation it is only for your understanding.

Upon completion of this course, you will be able to participate in a discussion with your

peers, cater the interview questions and take an examination on Rapid Manufacturing.

Identifying the tangible and intangible elements of Rapid Manufacturing, will also be the outcome

of this course. Select a process, tool, material for your product, define broadly the level

of Rapid Manufacturing systems from techniques, production lines, to digital facilities for

the entire enterprise. So, all these things are expected outcome of this course.

The first one is Additive Manufacturing. So, we will start with Additive Manufacturing

which is otherwise called as layered manufacturing. Additive Manufacturing is a layered based

automated fabrication process for making scale 3 dimensional physical objects directly from

a 3D cad data without using part depending tools this is very very important. Rapid Manufacturing

is I would like to build the 3 dimensional objects from fundamentally 2 dimensional layers.

I make layer by layer by layer, I stitch those layer by layer by layer and make it into a

3 D physical object. And this object is made without involving

any tools. It was originally called as 3D printing and is still frequently called that,

together with the well-established subtractive manufacturing such as milling or turning and

the formability manufacturing such as casting and forging, Additive Manufacturing provides

the third supporting pillar of the entire manufacturing technology. So, what we are

trying to say is here is a product, here are 3 pillars, one is subtractive pillar, the

other one is constant volume pillar subtractive pillar constant volume pillar and this is

additive pillar. So, constant you have metal forming and you have casting, here you have

joining and Additive Manufacturing. Subtractive you have the conventional and the non-conventional

machining processes. So, 3D printing is something which is which is very much talked about today.

When the first approaches to Additive Manufacturing entered the market in 1987, it is very new

it was called as Rapid Prototyping or it was called as Generative Manufacturing.

Generative Manufacturing, Rapid Manufacturing, Rapid Prototyping, Layered Prototyping, Freeform

Manufacturing, all these words and terminologies are interchanged and later you will realize

that 3D printing is a word, which is different from what we are talking about in rapid prototyping.

Both terms are still in use and in the past years many different names have been presented

and frequently more are added ok. Layered manufacturing is a very standard terminology

which is used which falls under Additive Manufacturing. Although each of the name is perfect from

the special viewpoint of its creator many of these causes confusion ok. Often this is

one reason why newcomers to the industry in particular sometimes feel lost in the field

of Additive Manufacturing. To obtain a brief overview a small selection

of the mostly used terms are structured according to a few families of keywords.

Often used terms include Rapid: Rapid Manufacturing, Rapid Technology, Rapid Prototyping, Rapid

Tooling. Additive: Additive Manufacturing, Additive Layer Manufacturing, Additive Digital

Manufacturing. These are the 3 terminologies which are used very exhaustively. So, this

is also commonly used and this is also commonly used.

Layer: layer based manufacturing, layer oriented manufacturing, layer manufacturing. These

are terminologies which are interchanged which are used in terms of layer.

Then the next one is digital fabrication and they also call it as digital mock up. So,

these are the terminologies which are used under this. Then direct people use Direct

Manufacturing and also Direct Tooling. These are terminologies which are used as part of

Additive Manufacturing and these are the terminologies which are used commonly.

Then at last 3D, we use 3D printing and 3D modelling. So, these are the terminologies

which are often used Rapid Manufacturing, Rapid Technology, Rapid Prototyping, Rapid

Tooling. When it comes to additive, it is Additive Manufacturing, Additive Layer Manufacturing,

Additive Digital Manufacturing it is almost the same. Layered Based Manufacturing, Layered

Oriented Manufacturing, Layer Manufacturing it is almost the same.

Digital fabrication, digital mock-up it is also used digital they both are the same and

direct manufacturing, direct tooling these are the terminologies which are used apart

from 3D printing and 3D modelling.

As Additive Manufacturing is a comparably young technology as compared to the other

two pillars whatever we have said there were almost no efforts for standardization for

many years, other than some preliminary work done in Germany in early 1990s. The standardization

of this has not still happened. Because of the non-standardization these processes are

not very much accepted in real time. Now, there is a lot of initiative which is

going towards standardization of additive manufactured parts. In 2007, a special recommendation

dedicated to rapid prototyping VDI 3404 was created under the supervision of German society

for Mechanical Engineers. In 2009, the American society for mechanical engineers in cooperation

with the American society for Testing and Materials started the development of their

own standards. Like what we have ISI, ISO, BSI, JSI these are standards. So, like that

people thought there is a need to initiate this rapid prototyping standards tool because

people did not realize in the initial days that this can be used for Rapid Manufacturing,

they realized it only for prototyping. But now since there is lot of need and requirements

have arised now standardization as of this Rapid Prototyping has also started.

In autumn 2009, the committee F42 on Additive Manufacturing issued F2792 dash 09e1 slash

F2792 slash and called it as a Standard Terminology for Additive Manufacturing Technologies they

release a standard. Among other definitions the name Additive Manufacturing was defined

by this committee. As it always takes time until newly defined terms are generally accepted,

a great variety of different terms increased by brand names and company driven terms are

still in use, sometimes even in competition to each other.

For a simple example what we realize is we always say let us take a xerox copy of your

document. Xerox was the company which made this photocopying technology or the photocopying

device. Actual process is photocopying, but we go ahead calling the process in terms of

the company name that is what is even still happening in rapid prototyping or in Rapid

Manufacturing or in Additive Manufacturing terminologies.

The principles of layered based technology; the term Additive Manufacturing like generative

manufacturing covers any imaginable way of adding materials in order to create a 3 dimensional

physical part. This is done from the data what is received or accepted from the virtual

form. The technical realization of Additive Manufacturing is based solely on layers and

therefore, it is called as layer based technology or layer oriented technology or even layer

technology. Consequently today the terms Additive Manufacturing, Generative Manufacturing and

layered based technologies are sometimes used synonymously. In the future as new additive

technologies may become available they will need to be classified within the current structure

of Rapid Manufacturing definition.

As an example the process called ballistic particle manufacturing BPM was introduced

already in the early 1990s, but vanished soon after. It added material from all spatial

directions by jetting discrete volume of the emerging object. This technology was additive,

but not layer based understand the difference this was particle by particle was impinged.

The principle of the layer based technology is to compose a 3-dimensional physical object

called part from many layers of mostly equal thickness.

Today we also talk about variable thickness, but primarily the machine is expected to do

a standard thickness only. Each layer is contoured according to the corresponding 3 dimensional

data set and put on to the top of the preceding one so; that means, to say I place one layer,

I place the next layer, I place the third layer I go on to the fourth layer. So, I place

layer by layer this is the layer we are talking about, this is the thickness we are talking

about and this is placed on top of the other. So, this is placed this is placed, this is

placed. So, each layer is contoured according this is only the side view suppose if I wanted

to look the plan view, you can have something like this on this ok. So, each layer is contoured

according to the corresponding 3 dimensional data set and put on to the top of the preceding

one.

So, this is how the layer looks like. So, here the principles of layer based technology

is explained. You can see here a plywood a thin wood sheet is carved layer by layer and

it is fixed one upon each other to get a final product like this. The principle of layer

based technology contoured layer left 3 dimensional made from stacking these layers one upon each

other we get the 3 dimensional part layer to part 2D layer to 3D part.

So, Additive Manufacturing if you see, it follows the schematic which is given here.

After an automated process of mesh fixing, slicing and hatching the desired structure

is transferred into the here I have taken one particular material called as photo polymer,

you can take any material into the material volume, by scanning the laser focus point

in a layer by layer process we are trying to develop it.

The 3D printing workflow is based on multiple photon absorption, polymerization is only

triggered in the high intensity region within the focal volume. So, what we are trying to

say is, we are trying to say, we are trying to develop a polymer part right. This polymer

part is developed from polymer layer. The layer whatever is getting the getting made

the starting material is here liquid. So, now, what do I do is, I have here laser which

comes down and then I have a tank in which photo polymer is filled.

So, this fellow tries to hit at a spot and this part alone because of the absorption

phenomena, it absorbs the UV light and gets cured. If I can move several dots can be created

and if I can make it into a hatch pattern then it forms a complete layer. So, one layer

is formed, then either I move the liquid polymer tank down or I move the laser little up you

try to get it. And interestingly you will have something called as f theta lens which

is used. So, this can scan and browse through a large area to create one layer of information.

So, when you give you a CAD data, this CAD data is first sliced. So, this is what I said

it is hatched. So, we are doing reverse of it polymer part, polymer layer, then in the

liquid. So, liquid so, first what we do is layer slicing is done then the slicing is

broken into hatching this is what is a hatching. There are several patterns of doing hatching

this hatching pattern where we can optimize the hatching pattern with respect to time,

with respect to strength we can do whatever we want. Polymerization is only to trigger

the high intensity region within the focal volume. So, what is a focal volume? This is

what it is. So, you can see here slice, this is the slice distance and inside a slice we

have hatch patterns between the hatches, between the hatches it is called as hatching distance

ok. And then What happens? You will try to make

a single layer. So, this is what is the slice distance, hatch distance you keep doing it

and when the laser tries to hit at the surface, I try to play with changing the focal plane.

So, moment I change the focal plane, the curing can happen at the surface, in between the

surface, below the surface at whatever z direction I want; that means, to say I can keep adding

the layer by layer within the polymer tank itself. So, this is what is adsorption, threshold

and here is, what is photo polymerization happening. This process is typically for a

photo polymer, photo polymer which is used as a liquid; where in which we use UV laser

to cure the photo polymer first in dot form, then in line form, then in layer form, then

layer stitching of layer you get a 3 dimensional object ok.

So, this is what is explained in this figure. So, Additive Manufacturing is an automated

and revolving process developed from the principle of layer based technology. It is characterized

by a process chain illustrated in the figure which is explained in the next slide. It starts

from a 3D CAD dataset that represents the part to be produced. In engineer the data

set is typically obtained by 3D CAD design or by scanning or other imaging technologies

such as computerized tomography scanning, CT-Scanning is also used for developing the

data independent of how it is obtained a 3D data set is first sliced into layer using

a computer and a special software. Thank you very much.