Rapid Prototyping
RP Overview:
Rapid Prototyping (RP) refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) files. RP machines are essentially "three dimensional printers", that allow designers to quickly create tangible prototypes of their designs. Such models have numerous uses. They make excellent visual aids for communicating design concepts with co-workers or customers. In addition, prototypes can be used for ergonomic or functional testing. For example, an aerospace engineer might create a scale model of an airfoil and use it to measure lift and drag forces in a wind tunnel, or a cell phone manufacturer might use a RP model to generate customer feedback on the look and feel of the next generation of handset.
Our Capabilities:
The Penn State Learning Factory currently has three machines - Zcorp Z402, Helisys LOM 1015, and Stratasys FDM-2000. A 3D Systems SLA250 is operated by the IE department. These machines are primarily for undergraduate student projects and are used in several courses in Mechanical, Industrial and Electrical Engineering. Graduate research projects and other paying Penn State organizations may use them on a space-available basis. Contact Carson Baird (863-6337) or John Lamancusa (863-3350) for further information.
Rapid Prototyping Educational Prices and Design Guidelines

Experiences:

ZCorp Z402 3D Printer: This is our newest (arrived April 2000) and fastest machine. It builds parts with a ceramic powder which is fused together by a liquid binder from an inkjet printer head. The printer heads tend to clog up if the machine is not used regularly, and must be replaced ($75/each). The parts tend to be delicate, but infiltrating with CA sealer helps a lot. The salesman will quote a low material cost, ($1/cubic inch) but they don't mention that the CA sealer ($25 per 50 gram bottle) and replacement printer heads are not inexpensive. ZCorp home page


Helisys LOM 1015:This was our first machine. It is very well suited for a teaching environment. It is the most economical process for parts that require a lot of material. Removal of excess material (requiring blades and paint scrapers) can be a safety concern. Wood carver gloves (with metal mesh) have drastically curtailed injuries. We only use the .004" paper. We use a hardware store variety of brush-on sanding sealer to coat the parts.

Our machine was upgraded with a heater hood, and servo motor X-Y plotter which increased the speed by about one-third. We have made parts for the Hershey Medical Center (artificial heart) and perhaps the first LOM parts to fly in space - on a NASA sounding rocket. Helisys is now out of business, and in the process they stiffed us for the remainder of our annual maintenance contract. The president of Helisys had the chutzpah of starting a new company that will service these machines, but won't honor old service contracts!.


Stratasys FDM-2000: After 2 nightmare years with a Genisys machine, we scrapped it for a FDM-2000 in January 1999. It is making nice parts. The design is simple and straightforward. We have been able to fix any problems (such as jammed nozzles) by ourselves or with the help of FedEx replacement parts from the land of sky blue waters (Minnesota). We use ABS material with the .012" nozzle for virtually all our parts. The water-washable support system is on order. Stratasys home page


3D Systems SLA250: Our SLA machine arrived in August of 1999. It is shared with the IE department and resides in the new Leonhard Building. Part washing is a concern with undergraduate students since the uncured resin is caustic to the skin. A nearby lightning strike taught us that a UPS (uninterruptible power supply) is worth the expense. 3D Systems home page


Rapid Prototyping Primer (complete document)
Individual sections: Rapid Prototyping Tutorial: Step-by-step instructions on building prototypes at the Learning Factory.

Examples: Pictures and descriptions of several prototypes made at the Learning Factory.

Rapid Prototyping Links: Various resources on the web

Instruction Materials:
Rapid Prototyping Lecture Slides - Part 1 (powerpoint format, 5.4MB) || (adobe acrobat format, 333KB)
Rapid Prototyping Lecture Slides - Part 2 (powerpoint format, 2.4MB) || (adobe acrobat format, 566KB)

Back to Learning Factory Homepage

Original version 5/13/98-- by Bill Palm
last updated 2 June 2003