Lecture 1
Rapid prototyping is a quick, cost effective way that describes ranges of manufacturing
fabrications of physical models and prototypes by using 3d Cad data. For validation, visualization
purposes and functional testing.
Technologies and process of RP are:
1. Additive Manufacturing
2. Subtractive Manufacturing
3. Hybrid Manufacturing
Techniques of assistive:
1. Stereolithography (SLA)
2. Selective Laser Sintering (SLS)
3. Fused Deposition Modeling (FDM)
4. Digital Light Processing (DLP)
5. PolyJet: Liquid
6. Binder Jetting
7. Material Jetting
Additive Manufacturing: is known as 3d printing, create objects layer by layer. Enables creation
of complex geometry, customized design, functional prototypes, cost effective, reduced waste,
design iterative and design freedom.
RP in biomedical engineering
1. Customized Medical Devices: Medical devices are designed specifically for a patient’s unique
body shape and needs. Doctors use imaging data like CT scans or MRIs to create 3D models.
These models help build implants, prosthetics, or orthotics that fit perfectly. Better fit and
comfort lead to improved outcomes, fewer complications, and a better quality of life for
patients.
2. Surgical Planning Tools: Surgeons use 3D models to prepare for complex surgeries. The 3D-
printed models of patient anatomy help surgeons plan the best surgical approach and even
practice the procedure beforehand. This reduces surgery time, minimizes risks, and makes
surgeries safer and more precise.
3. Prosthetics and Assistive Devices: Prosthetic limbs and assistive devices are customized and
quickly made using 3D printing. Prosthetists create lightweight and comfortable designs that
mimic natural movement, based on patient feedback. This approach ensures a better fit,
improved performance, and higher satisfaction for users.
4. Patient-Specific Anatomical Models: Detailed models of a patient’s body are created to assist
in planning surgeries and educating patients. models are 3D-printed using medical imaging
and help surgeons understand complex structures. They help doctors explain procedures,
train for surgeries, and involve patients in decisions, improving overall care.
5. Advancement in Tissue Engineering: 3D printing is used to create structures (scaffolds) that
help grow new tissues or organs. These scaffolds are carefully designed to allow living cells to
grow, aiding in tissue regeneration, disease research, and drug testing. It opens possibilities
for growing tissues for transplants, testing medicines, and studying diseases, paving the way
for breakthroughs in healthcare.
Lecture 2
Factors that built time is dependable on,
1. Chosen RP technology
2. Desired resolution
3. Size and complexity of an object
Factors that influence resolution,
1. Layer thickness
2. Chosen RP technology
3. Precision of RP machine
Importance and benefits of rapid prototyping in product development
1. Accelerated product development
2. Design iteration and feedback loop
3. Reduced costs and risks
4. Enhanced collaboration and communication
5. Improve quality and functionality
6. Design validation and visualization
7. Customers engagement and feedback
Rapid Prototyping Processes and Techniques
1. Concept development
2. Design iterative
3. Creation of prototype
4. Testing and evaluating
5. Iterative refinement
6. Finalization and production
Difference between design iterative and refinement is design iterative is in early stages and is
improvement of digital design. Refinement is on later stages and improvements on prototype.
Materials used in RP
1. Polymers: flexibility, impact resistance and chemical resistance
2. Metals: High strength, durable and heat resistance
3. Ceramic: High temperature resistance, electrical insulation and biocompatibility
4. Composites: High height to weight ratio, improve stiffness and enhanced electrical or
thermal conductivity.
Lecture 3
Classification of Rapid Prototyping Techniques Based on Processes and Material
Based on process
1. Additive: building products layer by layer (SLA and 3Dprinting)
2. Subtractive: Removing excess from a block or sheet (CNC machines and milling)
3. Formative: Applying external force such as heat, pressure or mechanical deformation
(thermal forming and blow molding)
Additive Subtractive
Builds objects by adding material layer Builds object by removing excess from
Definition
by layer (SLA, 3D printing) block or sheet (CNC machine, milling)
Starts with a 3d digital model, slicing it Starts with a block material and cut, drill
Process
and sequentially print slices and machines it.
Wide range of materials such as Limited range of materials that can be
Materials
polymers, ceramic, materials. easy for cut, drilled or machined.
Minimum waste because only adds Significant waste, such as chips, shavings
Waste
required material. and dust.
For more complex objects and internal For simpler objects and struggles with
Complexity
structures internal structures
Designfreedom Higher design freedom Limited design freedom
Takes more time based on size and Generally faster and for more complex
Time
complexity require some additional machines
Often required additional post
Minimal post processing with support
Postprocessing processing such as polishing, painting
structures easily removable.
and sanding
Application Aerospace, health care and automotive Machining, wood working and mold
Classification based on materials
1. Liquid phase
2. Solid phase
3. Gas phase
Liquid Solid Gas
Selective area laser
Stereolithography SLA Selective laser sintering SLS
deposition SALD
Fused deposition modeling
3D printing/Binder jetting
FDM
Ballistic particles Laser engineered net shapes
Manufacturing BPM LENS
Laminated object
Multi jet modeling MJM
manufacturing LOM
Shape deposition
manufacturing SDM
Advantages of SALD
1. Material flexibility
2. High precision
3. Material efficiency
4. Multimaterial compability
5. Repair and modification
Lecture 4
SLA components:
1. Vat
2. Ultraviolet laser
3. Built platform
4. Computer interface
Software: We will design the desired object by CAD it is digital representation of the object then
we will convert them to STL file, it is geometrical surface of object. And then it will go through
3D slicing so each slice individually is printed
Printing: A vat is filled with liquid photopolymer resin, and it will be exposed to UV laser, the
laser cures resin selectively layer by layer, wherever laser hits it solidifies. After each layer
platform will get lower (it rises in some models) for next layer.
And after all it will go under post processing it will be washed in alcohol. Then it will go under
post cure, this will make object achieve more strength and be more stable. And allows actual
layer curing to happen at minimum power requirement, this will speed up overall process time.
Advantages
1. High precision
2. Complex geometry
3. Wide range of material selection
4. Fast printing speed
Biomedical application
1. Anatomical models
2. Prosthetics and orthotics
3. Surgical guidance and implant
4. Drug delivery devices
Limitations
1. Limited size
2. Material Properties
3. Post processing
SLS working
1. Powdered material preparation
2. Laser scanning and sintering
3. Solidifying and bonding
4. Support structures and layer by layer build
5. Post processing
Advantages
1. Design freedom
2. Material versatility
3. High strength and durable
4. Batch production and customization
Biomedical application
1. Anatomical models
2. Tissue engineering (scaffold)
3. Prosthetic
4. Surgical guidance and implants
5. Biocompatibility and drug delivery system
Limitation
1. Material consideration, can work with many materials but options are limited
2. Build volume and scaling, they have specific build volumes for objects
3. Surface finish, often have rough surface
4. Powdered material safety and handling, that can be messy and harmful for inhalation
5. Design constraints, is design limited. It avoids overhanging and unsupported features
6. Equipment cost, sls machines are expensive to buy and maintain
1. Technology
Both use lasers, which are very accurate.
SLA (Stereolithography): A mirror guides the laser, but as it moves, the laser spot can lose its
shape slightly, reducing precision.
SLS (Selective Laser Sintering): Uses advanced systems that reduce this distortion, making it
more precise.
Laser Power:
o SLA lasers are less powerful, so you can safely view the print through tinted glass.
o SLS lasers are more powerful and dangerous, so SLS machines are fully enclosed to protect
users.
2. Materials
SLA:
o Uses liquid resin, which is expensive, toxic, and messy to handle.
o Post-processing is time-consuming because the resin must be cleaned and cured.
SLS:
o Uses powder, which is easier and safer to work with.
o Although powders are still expensive, cleaning them from finished parts is much simpler.
3. Finished Product
SLA:
o Produces parts with high detail but are usually brittle and not strong enough for
mechanical uses.
SLS:
o Produces parts with good detail and strong materials, including plastics and metals,
making them suitable for mechanical purposes.
4. Size
SLA:
o Smaller machines that can fit on a desk, ideal for personal or small-scale use.
SLS:
o Larger machines that require more space and power but can produce bigger parts or
multiple small parts faster, as they don’t need supports.
5. Cost
SLA:
o Cheaper printers are available (starting at ~$500).
o Resins are expensive, and costs add up over time.
SLS:
o Machines are much more expensive (starting at ~$5,000).
o Materials are costly but easier to manage.
Summary:
SLA is affordable, compact, and great for highly detailed models, but the parts are brittle and
require messy post-processing.
SLS is more expensive but produces stronger, functional parts and is better for larger or faster
production.
Lecture 5
FDM working principle
1. Filament material
2. Extrusion process
3. Layer by layer deposition
4. Build platform
Advantages
1. Cost effective
2. Material variety
3. Accessibility
4. Easy printing
5. Design flexibility
Biomedical applications
1. Anatomical models
2. Prosthetics and orthotics
3. Surgical guides and planning
4. Drug delivery system
5. Tissue engineering scaffold
6. Dental application
Limitations
1. Layer resolutions
2. Overhanging and angles
3. Support structures
Future development
1. Material innovation
2. Multimaterial printing
3. Enhance precision
4. Integration of additional technologies
DLP working principle
1. Micromirrors and DMD
2. Image formation
3. Light modulation
Advantages
1. Projection of large images with high brightness
2. Fast response time
3. High contrast ratio
4. Superior color production
Biomedical applications
1. 3D bioprinting
2. Surgical guidance
3. Optical imaging
4. Microfluid
Future developments
1. High resolution
2. Enhance energy efficiency
3. Integration with mobiles
4. Improve color accuracy
5. Advanced 3D projection
Lecture 6
Continuous Liquid Interface Production (CLIP): It uses oxygen and light to cure liquid resin
continuously without layering.
1. Faster printing
2. Smooth finish surface
Electron Beam Melting (EBM): It utilize electron beam to fuse powdered material together layer by
layer to create
1. Complex parts
2. High strength
3. Light weight
Digital Beam Melting (DBM): It uses electron beam to fuse powdered material
1. Complex parts
2. High accuracy
3. Excellent mechanical properties
Selective Deposition Lamination (SDL): It uses a sheet of material, cutting it and deposit it together
with thermal, pressure or adhesive.
1. Low cost
2. Full color
3. Architectural design
Direct metal laser sintering (DMLS): It uses high powered laser to fuse powdered material together
1. Intricate design
2. High accuracy
Binder Jetting: It uses powdered material and liquid binding is jetted on it to bond powder together
1. Scalability
2. Fast
Laminated Object Manufacturing (LOM): It uses material sheets, will be cut and deposit together
with heat or pressure.
1. Large objects
2. Cost effective
3. Molds
4. Architecture models
Multi Jet Fused (MJF): It uses inkjet technology with thermal energy to fuse powdered material
together
1. Fast
2. Multi materials
Lecture 7
CAD software allows engineers and designers to create, modify, analyze, and visualize 2D and 3D
models digitally
Basic functionalities of CAD Tools
1. Design creation
2. Visualization
3. Collaboration
Different types of CAD software
1. Mechanical
2. Architecture
3. Electrical
4. 3D Modeling
Benefits of using CAD software
1. Precision and accuracy
2. Visualization and simulation
3. Cost and time saving
Common CAD tools
1. 2D drafting tools
2. 3D modeling tools
3. Visualization and simulation
4. Parametric constraints
Challenges while using CAD
1. Complexity
2. Software compatibility
3. Hardware requirements
CAD in biomedical engineering
1. CAD in Medical Device Design
2. Customization and Patient-Specific Designs
3. Simulation and Analysis
4. Collaboration and Iterative Design
5. Integration with Additive Manufacturing
6. Regulatory Compliance
Benefits of Using RP in Medical Applications
1. Enhanced Customization
2. Improved Time-to-Market
3. Cost Savings
Design Considerations for RP in Medical Devices
1. Ergonomics
2. Biocompatibility
3. Sterilization
4. Functionality
Types of 3D Modeling Software
1. CAD Software
2. Sculpting Software
3. Sculpting Software
Process of Creating 3D Models
1. Conceptualize
2. Refine & Detail
3. Test & Validate
Types of CAD Techniques for Design Optimization
1. Parametric Modeling
2. Finite Element Analysis (FEA)
3. Topology Optimization
Challenges and Limitations of CAD Techniques for Design Optimization
1. Complexity Management
2. Design and Optimization Trade-offs
3. Expertise and Learning Curve
Future Trends and Potential Developments in RP for Medical Applications
1. Bioprinting
2. Smart Implants
3. Nanotechnology Integration
