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Rapid Prototyping (RP) Lab

​Scope of Lab​

Rapid Prototyping (RP) is the layer-by-layer fabrication of physical three dimensional models directly from a Computer Aided Design (CAD) model through a very efficient and highly flexible manufacturing process using Computer Aided Engineering (CAE) environment. This Additive Manufacturing (AM) technology is capable of printing out concepts and ideas into Three-Dimensional (3D) physical models. This additive manufacturing technique allows us to build complex geometries and shapes with ease which is otherwise very difficult or impossible to be produced using conventional manufacturing techniques.
All of the RP processes produce parts from CAD model. These CAD model is tessellated and sliced into thin sections, which are then produced by different RP technologies. The required supports for the part are generated automatically. The post processing step involves removal of supports and finishing. The figure below shows the compete process of RP.

Incharge of Lab

  • Dr Mushtaq Khan

Apparatus Name & Picture

The RP lab at NUST School of Mechanical and Manufacturing Engineering (SMME) is equipped with a 3D digitizer (Scanner)from Konica Minolta, a FAROARM Coordinate Measuring Machine (CMM) and a STRATASYS Fused Deposition Modeling (FDM) machine. This equipment provides the complete Reverse Engineering (RE) and Rapid Prototyping (RP) solution to the industry.
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Reverse Engineering (RE):
The 3D digitizer/ Scanner is capable of scanning objects both in gray and color mode. The polygon editing tool is used to PET enables you to control the VIVID and easily scan, polygonize, edit, and convert the scanned data into any of several common data formats. Multiple scans can be easily registered and merged into a single watertight polygonal model. Editing functions include: fill holes; filter irregular polygons and noise; and perform smoothing. PET exports data in industry-standard formats including: DXF, STL etc.
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for accurate transfer to a variety of 3D application like Inspection, Reverse Engineering and Rapid Prototyping. The FAROARM is a portable CMM that increases measurement productivity and flexibility and enhances accuracy in any production environment.
Computer Aided Design (CAD) Modeling:
The RP Lab at SMME uses Pro-Engineer CAD modeling software for designing 3D models. The RP Lab staff is fully trained with Pro-Engineer part modeling, assembly, mechanisms and optimization.
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Rapid Prototyping (RP):
The Fused Deposition Modeling (FDM) is a Rapid Prototyping machine which uses production-grade thermoplastics such as Acrylonitrile Butadiene Styrene (ABS), ABSi, polyphenylsulfone (PPSF), polycarbonate (PC) and Ultem 9085 (Fire retardant Thermoplastic), including PC-ABS. The FDM is used to check Form, Fit and Functionality of individual components and assemblies. FDM technology can also be used to manufacturing tools, such as jigs, fixtures and tooling masters. Due to the high flexibility of the process, it can produce intricate parts with ease.
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The RP Lab at SMME has an FDM titan machine which has a build envelope of 16 X 14 X 16 in (406 x 355 x 406 mm). Pro-Engineer CAD modeling software is used to design 3D models which are then converted to STL file for FDM. The Insight software provided with the FDM machine slices the STL file, generates supports and tool paths and sends the final data to FDM machine which produces the desired parts.