Table Of ContentRapid Prototyping and
Engineering Applications
Rapid Prototyping and
Engineering Applications
A Toolbox for Prototype Development
Second Edition
Fuewen Frank Liou
CRC Press
Taylor & Francis Group
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Library of Congress Cataloging‑in‑Publication Data
Names: Liou, Frank W., author.
Title: Rapid prototyping and engineering applications : a toolbox for
prototype development / authored by Fuewen Frank Liou.
Description: Second edition. | Boca Raton : Taylor & Francis, CRC Press,
2019. | Includes bibliographical references and index.
Identifiers: LCCN 2018045350| ISBN 9781498798921 (hardback : alk. paper) |
ISBN 9780429029721 (e-book : alk. paper)
Subjects: LCSH: Rapid prototyping. | Prototypes, Engineering—Data processing.
Classification: LCC TS171.8 .L56 2019 | DDC 620/.0042—dc23
LC record available at https://lccn.loc.gov/2018045350
Visit the Taylor & Francis Web site at
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Contents
Preface ...........................................................................................................................................xiii
Acknowledgments ........................................................................................................................xv
Author ..........................................................................................................................................xvii
Chapter 1 Introduction ...............................................................................................................1
1.1 Development of a successful product ................................................................................1
1.1.1 World-class manufacturing ...................................................................................1
1.1.2 Product definition ...................................................................................................4
1.1.3 Engineering design process ..................................................................................5
1.1.3.1 Identifying customer’s needs ...............................................................5
1.1.3.2 Converting needs into product design specifications ......................6
1.1.3.3 Engineering design ................................................................................6
1.1.3.4 Product prototyping ..............................................................................7
1.2 Product prototyping and its impact ...................................................................................7
1.2.1 Prototype design and innovation .........................................................................8
1.2.2 Impact on cost, quality, and time .......................................................................10
1.2.3 Key process requirements for rapid prototyping ............................................11
1.3 Product prototyping and product development ............................................................14
1.3.1 What is prototyping?............................................................................................14
1.3.2 Rapid prototyping in product development .....................................................17
References .......................................................................................................................................18
Chapter 2 Product prototyping ..............................................................................................19
2.1 Product prototyping ...........................................................................................................19
2.1.1 When is prototyping needed? .............................................................................19
2.1.2 Common mistakes and issues in product prototyping ..................................20
2.1.3 How to conduct prototyping? .............................................................................22
2.1.4 Physical prototype design procedure ................................................................24
2.1.4.1 Task 1: Prototype conceptual design .................................................24
2.1.4.2 Task 2: Configuration design of prototype parts and
components ...........................................................................................25
2.1.4.3 Task 3: Parametric design ...................................................................25
2.1.4.4 Task 4: Detailed design .......................................................................25
2.2 Prototype planning and management ............................................................................26
2.2.1 Project vision in project management ...............................................................26
2.2.2 How to manage prototype projects? ..................................................................27
2.2.3 Project risk management .....................................................................................31
v
vi Contents
2.3 Product and prototype cost estimation ...........................................................................34
2.3.1 Fundamental cost concepts .................................................................................35
2.3.2 Prototype cost estimation methods ...................................................................37
2.3.3 The cost complexities ...........................................................................................45
2.4 Prototype design methods ................................................................................................50
2.4.1 Engineering problem-solving .............................................................................50
2.4.2 Prototype design principles ................................................................................52
2.4.3 House of quality ...................................................................................................52
2.4.4 Product design specifications .............................................................................54
2.5 Prototype design tools .......................................................................................................61
2.5.1 Evaluating alternatives ........................................................................................61
2.5.1.1 First approach .......................................................................................62
2.5.1.2 Second approach ..................................................................................62
2.5.1.3 Third approach .....................................................................................63
2.5.2 Useful idea generation methods .........................................................................67
2.5.2.1 Morphological analysis .......................................................................68
2.5.2.2 Functional efficiency technique .........................................................68
2.6 Paper prototyping ...............................................................................................................71
2.6.1 Selecting a prototype ...........................................................................................71
2.6.1.1 Prototype fidelity .................................................................................71
2.6.2 Paper prototyping .................................................................................................72
2.6.3 User tests ................................................................................................................76
2.7 Learning from nature ........................................................................................................78
2.7.1 What can we learn from nature? ........................................................................78
2.7.2 Synectics .................................................................................................................80
2.7.2.1 Analogy .................................................................................................80
2.7.3 Better products—back to nature ........................................................................82
References .......................................................................................................................................83
Chapter 3 Modeling and virtual prototyping .....................................................................85
3.1 Mathematical modeling .....................................................................................................85
3.1.1 Relationship between mathematics and physics: an example .......................86
3.1.2 Using models for product and prototype design and evaluation .................90
3.1.2.1 Conservation of mass ..........................................................................90
3.1.2.2 Conservation of momentum ..............................................................91
3.1.2.3 Conservation of angular momentum ...............................................92
3.1.2.4 Conservation of energy .......................................................................92
3.1.2.5 Linear models .......................................................................................97
3.2 Modeling of physical systems .........................................................................................104
3.2.1 Types of modeling ..............................................................................................104
3.2.2 Examples of physical modeling ........................................................................105
3.3 Product modeling .............................................................................................................116
3.3.1 Product model .....................................................................................................116
3.3.2 Formal model ......................................................................................................119
3.4 Using commercial software for virtual prototyping ...................................................125
3.4.1 Dynamic analysis for prototype motion evaluation .....................................127
3.4.2 FEA for prototype structure evaluation ..........................................................129
3.5 Virtual reality and virtual prototyping ........................................................................134
Contents vii
3.5.1 Virtual prototyping ............................................................................................134
3.5.2 An AR system: an example ...............................................................................136
References .....................................................................................................................................138
Chapter 4 Material selections and product prototyping ................................................139
4.1 Prototyping materials ......................................................................................................139
4.1.1 Prototyping and material properties ...............................................................139
4.1.1.1 Material selection for high-fidelity prototypes .............................141
4.1.2 Material selection methods ...............................................................................142
4.1.3 Material selection processes for high-fidelity prototypes ............................143
4.2 Modeling of material properties ....................................................................................148
4.2.1 Aesthetic modeling .............................................................................................149
4.2.2 Warmth modeling ..............................................................................................149
4.2.3 Abrasion-resistant modeling .............................................................................149
4.2.4 Pitch modeling ....................................................................................................150
4.2.5 Sound absorption modeling .............................................................................150
4.2.6 Resilience modeling ...........................................................................................151
4.2.7 Friction modeling ...............................................................................................152
4.2.8 Thermal deformation .........................................................................................153
4.2.9 Ductility ...............................................................................................................154
4.3 Modeling and design of materials and structures ......................................................155
4.3.1 Cost of unit strength ..........................................................................................157
4.3.2 Cost of unit stiffness ...........................................................................................159
References .....................................................................................................................................164
Chapter 5 Direct digital prototyping and manufacturing .............................................165
5.1 Solid models and prototype representation .................................................................166
5.1.1 Solid modeling ....................................................................................................167
5.1.2 CAD data representation ...................................................................................170
5.1.2.1 Error analysis ......................................................................................175
5.2 Reverse engineering for digital representation ............................................................178
5.2.1 Reverse engineering and product prototyping ..............................................178
5.2.2 Reverse engineering process .............................................................................179
5.2.3 Ethics and reverse engineering ........................................................................184
5.3 Prototyping and manufacturing using CNC machining ...........................................184
5.3.1 Machine codes for process control ...................................................................185
5.3.2 Using CAD/CAM for digital manufacturing .................................................188
5.3.3 Developing a successful postprocessor ...........................................................197
5.3.3.1 Opening and closing codes ..............................................................199
5.3.3.2 Program detail formats .....................................................................200
5.3.3.3 Formats of specific G- and M-codes ................................................201
5.3.3.4 Transformation matrix ......................................................................201
5.3.3.5 Formation of the transformation matrix for the A- and
B-axis rotation ....................................................................................202
5.3.3.6 Limitation of machine mobility around A- and B-axes ...............203
5.3.3.7 B tilt table ............................................................................................204
5.3.3.8 A tilt table ............................................................................................204
5.3.3.9 Axis limits ...........................................................................................204
viii Contents
5.4 Fully automated digital prototyping and manufacturing .........................................208
5.4.1 Process planning and digital fabrication ........................................................208
5.4.2 Feature-based design and fabrication .............................................................209
5.4.3 User-assisted feature-based design .................................................................211
References .....................................................................................................................................213
Chapter 6 Additive manufacturing processes ...................................................................215
6.1 Additive manufacturing overview ................................................................................215
6.1.1 What is AM ..........................................................................................................216
6.1.1.1 AM applications .................................................................................216
6.1.2 What are the alternatives to AM processes? ...................................................217
6.1.3 Producing functional parts ...............................................................................220
6.2 Additive manufacturing procedure ...............................................................................221
6.2.1 Why is AM process faster? ................................................................................222
6.2.2 A typical AM process .........................................................................................222
6.2.3 Why STL files? .....................................................................................................223
6.2.4 Converting STL file from various CAD files ..................................................225
6.2.5 Controlling part accuracy in STL format ........................................................226
6.2.6 Slicing the STL file ..............................................................................................231
6.2.7 Building an AM part using an STL file ...........................................................236
6.2.8 AM file format .....................................................................................................237
6.3 Liquid-based AM processes ............................................................................................240
6.3.1 Stereolithography process .................................................................................240
6.3.2 Mask-based process ............................................................................................244
6.3.3 Inject-based process............................................................................................246
6.4 Solid-based AM processes ...............................................................................................249
6.4.1 Extrusion-based process ....................................................................................250
6.4.2 Contour-cutting process ....................................................................................254
6.4.2.1 The process .........................................................................................255
6.4.3 UC process (Ultrasonic Consolidation™) .......................................................256
6.5 Powder-based AM processes ..........................................................................................259
6.5.1 PBF processes ......................................................................................................260
6.5.1.1 PBF process steps ...............................................................................262
6.5.2 3 D inject printing process..................................................................................267
6.5.3 Direct laser deposition .......................................................................................270
6.5.3.1 Advantages of DLD process .............................................................276
6.5.3.2 Limitations of DLD process ..............................................................277
6.5.4 EBM process ........................................................................................................277
6.5.5 Hybrid material deposition and removal process .........................................279
6.6 Summary and future AM processes..............................................................................284
References .....................................................................................................................................285
Chapter 7 Building a prototype using off-the-shelf components .................................287
7.1 How to decide what to purchase? ..................................................................................287
7.1.1 Purchasing decision for a prototype ................................................................288
7.1.2 What to purchase? ..............................................................................................289
7.1.3 Draw a flow diagram of signals and components .........................................293
7.1.4 Prioritize the precision of the system ..............................................................295
Contents ix
7.2 How to find the catalogs that gave the needed components? ....................................298
7.2.1 Evaluating companies and products ...............................................................299
7.2.2 Component selection ..........................................................................................299
7.3 How to ensure that the purchased components will work together? ......................303
7.4 Tolerance analysis .............................................................................................................313
7.5 Tolerance stack analysis ...................................................................................................320
7.6 Assembly stacks ................................................................................................................327
7.7 Process capability .............................................................................................................331
7.8 Statistical tolerance analysis............................................................................................336
7.9 Case study: conceptual design of a chamber cover .....................................................340
7.9.1 Problem description ...........................................................................................340
7.9.2 Requirement definition ......................................................................................341
7.9.3 Component identification and design .............................................................341
7.9.4 Tolerance analysis ...............................................................................................343
7.9.5 A focused prototype ..........................................................................................345
References .....................................................................................................................................345
Chapter 8 Prototyping of automated systems ...................................................................347
8.1 Actuators ............................................................................................................................347
8.1.1 Types of actuators ...............................................................................................348
8.1.2 Drives ...................................................................................................................350
8.1.3 When to choose an actuator ..............................................................................353
8.1.3.1 Base/manifold-mount solenoid control valves ..............................353
8.2 Sensors ...............................................................................................................................356
8.2.1 Sensor classification based on sensor technology .........................................358
8.2.1.1 Manual switches ................................................................................359
8.2.1.2 Proximity switch ................................................................................359
8.2.1.3 Photosensor ........................................................................................359
8.2.1.4 Fiber optics sensor .............................................................................361
8.2.1.5 Infrared sensor ...................................................................................362
8.2.2 Sensor selection ...................................................................................................362
8.3 Controllers and analyzers ...............................................................................................364
8.3.1 PLC control ..........................................................................................................365
8.3.2 Computer control ................................................................................................367
8.4 Mechanisms.......................................................................................................................385
8.4.1 Mechanisms in automation ...............................................................................385
8.4.2 Applications and selection of mechanisms ....................................................391
8.4.2.1 Linear or reciprocating input, linear output ..................................391
8.4.2.2 Rotary input, rotary output ..............................................................394
8.4.2.3 Rotary input, reciprocating output .................................................395
8.4.2.4 Rotary input, intermittent output ....................................................397
8.4.2.5 Rotary input, irregular output .........................................................398
8.4.2.6 Reciprocating input, rotary output .................................................398
8.4.2.7 Reciprocating input, oscillation output ..........................................399
8.4.2.8 Reciprocating input, intermittent output .......................................401
8.4.2.9 Reciprocating input, irregular output ............................................401
8.4.2.10 Oscillation input, rotary output .......................................................401
8.4.2.11 O scillation input, reciprocating output ..........................................402
