Modelling and optimisation of Rapid Prototyping

This paper proposes a Virtual Reality (VR) system for modelling and optimisation of Rapid Prototyping (RP) processes. The system aims to reduce the manufacturing risks of prototypes early in a product development cycle, and hence, reduces the number of costly design-build-test cycles. It involves modelling and simulation of RP in a virtual system, which facilitates visualisation and testing the effects of process parameters on the part quality. Modelling of RP is based on quantifying the measures of part quality, which includes accuracy, build-time and efficiency with orientation, layer thickness and hatch distance. A mathematical model has been developed to estimate the build-time of the Selective Laser Sintering (SLS) process. The model incorporates various process parameters like layer thickness; hatch space, bed temperatures, laser power and sinter factor, etc. It has been integrated with the virtual simulation system to provide a test-bed to optimise the process parameters. (C) 2002 Elsevier Science B.V. All rights reserved.