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RAPIDPROTOTYPINGVERSUSVIRTUALPROTOTYPINGINPRODUCTDESIGNANDMANUFACTURINGCKCHUA1,SHTEH1ANDRKLGAY2SCHOOLOFMECHANICALAND2GINTICINSTITUTEOFMANUFACTURINGTECHNOLOGY,NANYANGTECHNOLOGICALUNIVERSITY,SINGAPOREABSTRACTRAPIDPROTOTYPINGRPISTHEPRODUCTIONOFAPHYSICALMODELFROMACOMPUTERMODELWITHOUTTHENEEDFORANYJIGORFIXTUREORNUMERICALLYCONTROLLEDNCPROGRAMMINGTHISTECHNOLOGYHASALSOBEENREFERREDTOASLAYERMANUFACTURING,MATERIALDEPOSITMANUFACTURING,MATERIALADDITIONMANUFACTURING,SOLIDFREEFORMMANUFACTURINGANDTHREEDIMENSIONALPRINTINGINTHELASTDECADE,ANUMBEROFRPTECHNIQUESHASBEENDEVELOPEDTHESETECHNIQUESUSEDIFFERENTAPPROACHESORMATERIALSINPRODUCINGPROTOTYPESANDTHEYGIVEVARYINGSHRINKAGE,SURFACEFINISHANDACCURACYVIRTUALPROTOTYPINGVPISTHEANALYSISANDSIMULATIONCARRIEDOUTONAFULLYDEVELOPEDCOMPUTERMODEL,THEREFOREPERFORMINGTHESAMETESTSASTHOSEONTHEPHYSICALPROTOTYPESITISALSOSOMETIMESREFERREDTOASCOMPUTERAIDEDENGINEERINGCAEORENGINEERINGANALYSISSIMULATIONTHISPAPERDESCRIBESACOMPARATIVESTUDYOFTHETWOPROTOTYPINGTECHNOLOGIESWITHRESPECTTOTHEIRRELEVANCEINPRODUCTDESIGNANDMANUFACTURETHESTUDYINVESTIGATESTHESUITABILITYANDEFFECTIVENESSOFBOTHTECHNOLOGIESINTHEVARIOUSASPECTSOFPROTOTYPING,WHICHISPARTANDPARCELOFANOVERALLDESIGNANDMANUFACTURINGCYCLEKEYWORDSPRODUCTDESIGNRAPIDPROTOTYPINGVIRTUALPROTOTYPING1INTRODUCTIONRAPIDPROTOTYPINGRPISEMERGINGASAKEYPROTOTYPINGTECHNOLOGYWITHITSABILITYTOPRODUCEEVENCOMPLICATEDPARTSVIRTUALLYOVERNIGHTITENABLESPRODUCTDESIGNERSTOSHORTENTHEPRODUCTDESIGNANDDEVELOPMENTPROCESSTHECOMINGOFAGEOFTHISTECHNOLOGYISCLEARLYREFLECTEDINTHEINCLUSIONOFASTEREOLITHOGRAPHYSTLFILEGENERATORINMOST,IFNOTALL,CADSYSTEMSTODAYTHESTLFILEISTHEDEFACTOSTANDARDUSEDBYRPSYSTEMSINTHEREPRESENTATIONOFTHESOLID3DCADMODELSWHILERPISARELATIVELYYOUNGTECHNOLOGY,VIRTUALPROTOTYPINGVPHASBEENINSTEADYDEVELOPMENTSINCETHE1970SINMANYGUISESVIRTUALPROTOTYPINGISTAKENTOMEANTHETESTINGANDANALYSISOF3DSOLIDMODELSONCOMPUTINGPLATFORMSTODAY,VPISOFTENTIGHTLYINTEGRATEDWITHCAD/CAMSOFTWAREANDSOMETIMESREFERREDTOASCAEPACKAGESITPROVIDESTHEABILITYTOTESTPARTBEHAVIOURINASIMULATEDCONTEXTWITHOUTTHENEEDTOMANUFACTURETHEPARTFIRST12DEFINITIONSOFRPANDVPRAPIDPROTOTYPINGRPISAWIDELYUSEDTERMINENGINEERING,PARTICULARLYINTHECOMPUTERSOFTWAREINDUSTRYWHEREITWASFIRSTCOINEDTODESCRIBERAPIDSOFTWAREDEVELOPMENTTHISTERMHASALSOBEENADOPTEDBYTHEMANUFACTURINGINDUSTRYTOCHARACTERISETHECONSTRUCTIONOFPHYSICALPROTOTYPESFROMASOLID,POWDER,ORLIQUIDINASHORTPERIODOFTIMEWHENCOMPAREDTO“TRADITIONAL”SUBTRACTIVEMACHININGMETHODSTHISTECHNOLOGYHASALSOBEENVARIOUSLYREFERREDTOASLAYERMANUFACTURING,MATERIALDEPOSITMANUFACTURING,MATERIALADDITIONMANUFACTURING,SOLIDFREEFORMMANUFACTURINGANDTHREEDIMENSIONALPRINTING2VIRTUALPROTOTYPINGVPREFERSTOTHECREATIONOFAMODELINTHECOMPUTER,OFTENREFERREDTOASCAD/CAM/CAEVIRTUALORCOMPUTATIONALPROTOTYPINGISGENERALLYUNDERSTOODTOBETHECONSTRUCTIONMODELSOFPRODUCTSFORTHEPURPOSEOFREALISTICGRAPHICALSIMULATION1INTHISPAPER,VPWILLREFERTOTHESIMULATION,VIRTUALREALITYANDMANUFACTURINGPROCESSDESIGNDOMAINS3NEVERTHELESS,THEREAREMANYAREASWHERETHEDISTINCTIONBETWEENRPANDVPISBLURREDASRPSYSTEMSRELYONCADSYSTEMSTOGENERATETHEFILESNEEDEDTOPRODUCETHEPROTOTYPE,ITWOULDSEEMTHATRPISADOWNSTREAMPROCESSFROMVPINTHEPRODUCTORPARTDEVELOPMENTCYCLEINDEED,PRATTSDEFINITIONOFVPREVEALSTHEFACTTHATVPISATERMWHICHISLOOSELYUSEDINTHEPROTOTYPINGCOMMUNITYASSUCH,ITWOULDBEAPPROPRIATETOCLEARLYDEFINEBOTHRPANDVPRAPIDPROTOTYPINGWILLBETAKENTOMEAN,ASABOVE,THEPRODUCTIONOFAPHYSICALMODELFROMACOMPUTERMODELWITHOUTTHENEEDOFANYJIGORFIXTUREORNCPROGRAMMINGTHISALSOINCLUDESOTHERRELATEDPROCESSESANDAPPLICATIONSWHICHUSERPPRODUCEDOBJECTS,SUCHASRAPIDTOOLINGSIMILARLY,VPISDEFINEDASTHESUBSEQUENTMANIPULATIONOFASOLIDCADMODELASASUBSTITUTEFORAPHYSICALPROTOTYPEFORTHEPURPOSESOFSIMULATIONANDANALYSIS,ANDISNOTINCLUSIVEOFTHECONSTRUCTIONOFTHESOLID3DMODELVPINCLUDESTHEFOLLOWINGFUNCTIONS1FINITEELEMENTANALYSIS2MECHANICALFORM,FITANDINTERFERENCECHECKING3MECHANICALSIMULATION4VIRTUALREALITYAPPLICATIONS5COSMETICMODELLING6ASSEMBLABILITYTHERELATIONSHIPSBETWEENRPANDVPARESHOWNINFIG1FIG1CLASSIFICATIONOFRPANDVP3PROTOTYPINGINSINGAPORETWOSELECTEDMULTINATIONALCOMPANIESONEAMERICANANDONEFRENCHBASEDINSINGAPOREWITHSIGNIFICANTPRODUCTDEVELOPMENTACTIVITIESSHOWEDDIFFERINGAPPROACHESTOBOTHRPANDVPBOTHUSERPINTHEIRPROTOTYPINGACTIVITIESTHEFIRSTCOMPANY,B,PLACEDMOREEMPHASISONVIRTUALPROTOTYPINGITMANUFACTURESTELECOMMUNICATIONSEQUIPMENTSUCHASPAGERSANDHANDPHONESITISMOVINGALLPROTOTYPINGAPPLICATIONSUPSTREAM,WHICHISTOMOVEPROTOTYPINGFROMRPTOVPATPRESENT,THEIRRPMODELSAREUSEDONLYFORPROOFOFCONCEPTANDMARKETINGPURPOSESOTHERPROTOTYPINGACTIVITIESAREBEINGCARRIEDOUTWITHVPTHESECONDCOMPANY,C,MANUFACTURESCONSUMERELECTRONICSPRODUCTSSUCHASTELEVISIONSETS,VIDEOCASSETTERECORDERSANDTELEPHONESITUSESVPONLYASATOOLTOCREATEASOLID3DMODELFROMTHESOLID3DMODEL,CGENERATESTHESTLFILENEEDEDTOPRODUCETHERPPROTOTYPECOMPANYCTHENUSESTHERPPARTASAMASTERFORSILICONERUBBERMOULDSTOPRODUCEALIMITEDNUMBEROFPHYSICALABSPOLYACRYLONITRITEBUTADIENESTYRENEPROTOTYPESFORTHEVARIOUSPROTOTYPINGTESTSANDSIMULATIONCOMPANYBINTENDSTOMOVEMOREPROTOTYPINGTOVP,RATHERTHANUSINGPHYSICALMODELSVIRTUALPROTOTYPINGALLOWSFORIMPROVEMENTSINRELIABILITYANDQUALITYASWELLASREDUCINGCOSTSMANIPULATIONOFVIRTUALPROTOTYPESMAKESITEASIERFORBTOIMPLEMENTDESIGNIMPROVEMENTSCOMPAREDTOANITERATIVECYCLEUSINGPHYSICALPROTOTYPESCOMPANYBDRAFTSTHECADMODELSINPRO/ENGINEER,THENUSESPATRANTOPREPROCESSTHEMODELSSTATICFINITEELEMENTANALYSISFEAISCARRIEDOUTWITHABAQUSSTANDARDWHEREASDYNAMICSCENARIOSAREANALYSEDWITHABAQUSEXPLICITALIAS/WAVEFRONTISUSEDFORCOSMETICMODELLINGWHENPRESENTINGDIFFERENTCONCEPTUALANDACTUALDESIGNSTHEBULKOFTHEVPCARRIEDOUTBYBUSESFEA,WHICHTYPICALLYTAKES46WEEKSFORAPAGERDESIGNOFALLTHEFEACARRIEDOUT,THEMAJORITYARECONCENTRATEDONSTRUCTURALSTRENGTHSTATICANALYSISANDDROPTESTDYNAMICANALYSISVIBRATIONTESTSAREOCCASIONALLYCARRIEDOUTSOMECOSMETICMODELLINGISCARRIEDOUT,BUTUSUALLYONLYFORPRESENTATIONPURPOSESFINITEELEMENTANALYSISISUSEDTOINVESTIGATETHEFOLLOWINGPROBLEMSRELATIVECOMPARISONOFDIFFERENTDESIGNOPTIONSTOSEEHOWONEDESIGNCOMPARESTOANOTHERPOSSIBLEFAILUREMODESARE1TOEVALUATEADESIGNCHANGEORDESIGNCORRECTION2TOASSESSTHEPOSSIBILITYOFFAILURE,BASEDONPASTEXPERIENCE3TOMAKESOMEEDUCATEDGUESSCORRELATIONWITHPHYSICALTESTING4TOTRYTOIDENTIFYWHATINITIATEDAFAILUREACCORDINGTOB,THEDRAWBACKOFVPISTHATITCANNOTSIMULATEPROCESSPROBLEMSEFFICIENTLYANDEFFECTIVELYTHEACCURACYOFFEAISALSOLIMITEDBECAUSEOFTHEINCONSISTENTBEHAVIOUROFMATERIALTHEAMOUNTOFCOMPUTINGPOWERALSODETERMINESTHEACCURACYOFFEATHEAPPLICATIONOFRPISRATHERLIMITEDINBTHEINHOUSELAMINATEDOBJECTMANUFACTURINGLOMRPSYSTEMISUSEDTOPRODUCEDESIGNPROTOTYPESFORPROOFOFCONCEPTONLY,ANDNOTGEOMETRICALPROTOTYPESCOMPANYCUSESRPHEAVILY,BUTHASVERYLITTLEVPTHEPARTSPRODUCEDUSINGRPRANGEFROMAUDIOPRODUCTSTO29INTELEVISIONCASINGSTYPICALLY,ITTAKES1YEARFROMTHECONCEPTIONOFTHEPRODUCTTOTHESALEOFTHEPRODUCTCOMPANYCAIMSTOPROTOTYPEALLMOSTLYPLASTICPARTSBYRPACOMPARISONBETWEENNUMERICALLYCONTROLLEDNCMACHININGOFPROTOTYPESFROMABSAGAINSTRPISSHOWNINTABLE1COMPANYCPROJECTED50SAVINGSUSINGANINHOUSERPSYSTEMVERSUSANNCMACHININGSYSTEMCADMODELSARECREATEDUSINGIDEASTHESTLFORMATISTHENCREATEDFORPRODUCTIONOFTHERPPARTTHEMAINPURPOSEOFTHERPPARTSISTOVERIFYTHEDESIGNRAPIDPROTOTYPINGPARTSAREUSEDFORTHEFOLLOWINGFUNCTIONS1FORMFITTING2ERGONOMICSCHECK3PROOFOFCONCEPTTOCONFIRMDESIGNWITHINDUSTRIALDESIGNERS4MANUFACTURABILITYDESIGNFORTOOLING,DESIGNFORASSEMBLABILITY5RELIABILITYCHECKWHETHERPARTDISLODGESORBREAKSWHENFORCEAPPLIED,ESPECIALLYSNAPONCOVERS6KINEMATICCHECKCOMPANYCOFFERSSOMEINSIGHTINTOTHELIMITATIONSOFVP,INTHATVPISUNABLETOMODEL1TACTILEFEELINGFORBUTTONSNOTQUANTIFIEDMAYBEABLETOVPIFABLETOQUANTIFY“PRESSING”FORCE2ASSEMBLABILITYEGPCBSINSERTEDATANANGLE,DIFFICULTTOVISUALISE4CASESTUDY1PROTOTYPINGOFATELEPHONEHANDSETTHISCASESTUDYINVESTIGATESTHEDESIGNVERIFICATION,ASSEMBLY,INTERFERENCECHECKANDFORMFITTINGASPECTSOFBOTHTHERPANDVPMODELTHEPRODUCTIONABS,RPANDVPPARTSORMODELSWEREEVALUATEDINTHEABOVEASPECTSTHERPSYSTEMUSEDHEREISTHESTEREOLITHOGRAPHYAPPARATUSSLABOTHTHEABSANDRPPARTSARESHOWNINFIG2INSPECTIONOFTHERPPARTSREVEALTHAT1THESURFACEFINISHWASMUCHPOORERTHANINTHEABSPART2WARPAGEWASCLEARLYEVIDENTSEEFIG341DESIGNVERIFICATIONASATRUEDIMENSIONALPHYSICALPART,THERPMODELISABLETOGIVETHEDESIGNERASENSEOFSIZEESTIMATIONTHEJUDGEMENTOFAVPPARTCANBEERRONEOUSBECAUSEPARTSAREOFTENAUTOMATICALLYSIZEDTOFITTHEVIEWINGWINDOWANOTHERADVANTAGEOFAPHYSICALPARTISTHATITALLOWSFORERGONOMICCHECKS,RANGINGFROMTHEFITOFATELECOMMUNICATIONSDEVICEINAUSERSPALMTOTHEINSPECTIONOFPOTENTIALLYDANGEROUSCORNERSANDEDGESALSO,ITOFFERSTACTILEINSPECTIONWHICHISCRUCIALINPRODUCTSFORWHICHERGONOMICSISIMPORTANT,SUCHASTOUCHBUTTONSONAUDIOORVIDEOPRODUCTS,WHICHISNOTPOSSIBLEONVPSYSTEMSROUNDEDEDGESWHICHAPPEARINNOCUOUSONAVPMODELMAYPROVETOBEUNSAFEUPONSCRUTINYOFTHERPPARTABOVEALL,MOSTRPPARTSAREPRODUCEDFORAESTHETICEVALUATIONPURPOSESAESTHETICEVALUATIONISALSOPOSSIBLEONVPMODELSALLCADSOFTWAREALLOWSTHEMODELTOBEVIEWEDINANYSPATIALORIENTATION,ALONGWITHATLEASTRUDIMENTARYRENDERINGCAPABILITIESITISTHENPOSSIBLETOVIEWTHEPARTUNDERTHEDESIREDSIMULATEDLIGHTINGCONDITIONSWITHMILLIONSOFSHADINGANDCOLOURCOMBINATIONSRPPARTSCANNOTBECOLOURED,THUSSURFACEPREPARATIONANDPAINTINGINTRODUCEADDITIONALFINISHINGPROCESSESANYVISIBLYAPPARENTDESIGNDISCREPANCIESCOULDBEIMMEDIATELYRECTIFIEDWITHOUTHAVINGTOINVESTINAPHYSICALPARTITALSOALLOWSDESIGNERSTOEVALUATETHEAESTHETICSOFTHEDESIGNANDMAKECORRECTIONS,IFNECESSARYINTHECASEOFMOSTMULTINATIONALCOMPANIES,THEDESIGNANDMANUFACTURINGFACILITIESAREOFTENACONSIDERABLEDISTANCEAPARTANDINDIFFERENTCOUNTRIESANDCONTINENTSTHEEASEWITHWHICHCADFILESCANBESENTANDRECEIVEDVIAELECTRONICMEANSGREATLYHELPSTHEDESIGNPROCESS,BEITITERATIVEORCONCURRENTWITHIDENTICALORCOMPATIBLECADSOFTWARE,THEPROTOTYPINGPROCESSCANBESWIFTANDCHEAPANYDESIGNCHANGEOFTHEVIRTUALPROTOTYPECANBEMADEALMOSTINSTANTLYAVAILABLETOALLPARTIESINVOLVEDINTHEDESIGNPROCESS42ASSEMBLYASSEMBLYOFRPPARTSMUSTBECARRIEDOUTQUICKLY,ASWARPAGEANDSHRINKAGEINCREASESWITHTIMEWARPAGEISAFUNCTIONOFBOTHPARTGEOMETRYDESIGNANDSHRINKAGEALLBUTTHEBESTDESIGNEDPARTSSUFFERFROMVARYINGDEGREESOFWARPAGEANDSHRINKAGESOMERPMATERIALSUCHASTHESLAINHERENTLYSHRINKSANDTHEPARTISACTUALLYBUILTSLIGHTLYLARGERTOALLOWITTOSHRINKTOITSPROPERDIMENSIONSWITHSUCHARRANGEMENTS,ASSEMBLYISPOSSIBLEBUTISOFTENHAMPEREDBYWARPAGEAND/ORSHRINKAGESOMEPARTSCANBEMATEDONLYWITHTHEAPPL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HEYMUSTBEJOINEDTOTHEAPPROPRIATEADJACENTPOINTSTOFORMCURVESCONFUSIONSOMETIMESOCCURSWHENASURFACEFOLDSBACKWHILEAPOINT“BELOW”ISTHENEARESTPOINT,ITMAYNOTBEANADJACENTPOINTTHESECURVESMUSTTHENBEINDIVIDUALLYANDMANUALLYSELECTEDTODEFINESURFACESAGAIN,CAREMUSTBETAKENTOENSURETHATTHEAPPROPRIATESURFACESWHICHAPPROXIMATETHEORIGINALSURFACESAREFORMEDAFTERTHESURFACESAREFORMED,THEYARECONNECTEDTOFORMPATCHESORQUILTSTHESEQUILTSARETHENCOMBINEDTOFORMASURFACEMODELIFTHESURFACEMODELISFULLYENCLOSED,THECADSYSTEMMAYTHENCONVERTITINTOASHELLORSOLID3DMODELTHECOMPLEXITYANDSHAPEOFTHEHUMANBODYALSOPRESENTSPROBLEMSMOSTOFTHEEXTRACTEDOUTLINESAREREPRESENTEDASCOMPLICATEDBEZIERCURVESAMAPPINGALGORITHMSOMETIMESFAILSTOCOMBINETHESEBEZIEROUTLINESTOFORM3DDATASO,ITISNECESSARYTHATTHISPROCESSBESUPPORTEDBYHAND6HUMANSUPERVISIONISALSOREQUIREDWHERESOFTWAREISUNABLETORECOGNISEFEATURESSUCHASJOINTSWHEREBONESTRUCTURESABUTTHEDATAMUSTBESEPARATEDINTOINDIVIDUALCOMPONENTSDISARTICULATIONINORDERTOEVALUATEAFUNCTIONEGAJAWJOINTDIRECTINTERFACINGHASTWOMAJORPROBLEMSTHEDATAFROMTHECTSCANNERAREINTHEFORMOFSHADEDIMAGESANDAREAUTOMATICALLYSEGMENTEDWHILEITISPOSSIBLETOCALCULATETRIANGLESFROMTHEIMAGES,THEYDONOTCONTAINENOUGHSURFACEINFORMATIONTHEREFORE,ITISDIFFICULTFORTHERPSYSTEMWHICHREQUIRESSUPPORTSTOCONSTRUCTTHEAPPROPRIATESUPPORTSTRUCTURESSECONDLY,THEINTERPOLATIONFROMSUCCESSIVECONTOURSOBTAINEDFROMTHESEGMENTATIONISNOTEVIDENTTHECTSCANNERHASATHRESHOLDFILTERTOISOLATEREGIONSWITHINTHEDESIREDDENSITYRANGEWHENTISSUEDENSITYRANGESACROSSTHISTHRESHOLDSETTING,THEREAREPROBLEMSINIDENTIFYINGTHETISSUEFOREXAMPLE,FORCORTICALBONEHIGHDENSITYWITHASTRUCTURELARGERTHANTHEVOXELDIMENSION,SURFACESAREWELLDEFINEDANDTHETRANSITIONSAREEASYTORECOGNISEWHENLOWERDENSITYSTRUCTURESARESCANNEDCANCEROUSBONEORTHESTRUCTUREISSOTHINTHATITONLYPARTIALLYFILLSTHEVOXEL,THEDENSITYMEASUREDATTHESURFACESMAYNOTSURPASSTHETHRESHOLDCONSEQUENTLY,AFIXEDTHRESHOLDFILTERWILLRESULTINSHRINKINGTHESTRUCTUREDIMENSIONORCREATINGAVOID7,SOMOSTRESEARCHISFOCUSEDONTHESTLINTERFACEVIRTUALPROTOTYPINGHASMOREAPPLICATIONSINBIOMECHANICSCADSYSTEMSAREUSEDTODESIGNPROSTHESESANDTHESIMULATIONANDANALYSISMODULESAREUSEDTOHELPREFINETHEDESIGNOFTHEPARTFINITEELEMENTANALYSISISAUSEFULTOOLINTHEDESIGNOFLOADBEARINGPROSTHESESSUCHASKNEESANDHIPSKINEMATICSSIMULATIONANDANALYSISISAPPLIEDWHERETHERANGEOFMOVEMENTOFTHELIMBSLINKEDBYTHEPROSTHESESISSPECIFIEDTHERMALSIMULATIONISNOTUSUALLYCARRIEDOUTASTHESERVICECONDITIONFORTHEPROSTHESESISANEVEN37CRAPIDPROTOTYPINGPARTSPRODUCEDFORTHEPROSTHESESAREFORTHEPROOFOFTHECONCEPTASWELLASFORSIZEESTIMATIONFORMFITTINGORASSEMBLYCANBEDONEINSOMECASESBUTISNOTPOSSIBLEFOROTHERSSUCHASABALLSOCKETJOINTFOUNDINAHIPPROSTHESISFORPROSTHESESWITHMOVINGPARTS,AROUGHKINEMATICSCHECKCANBEPERFORMED52FINITEELEMENTMODELLINGINVESTIGATIONTHISCASESTUDYEXPLORESTHEBASICFINITEELEMENTMODELINGFEMCAPABILITIESOFVPPACKAGESANDHOWCORRESPONDINGRPPARTSCOMPARETOTHEMTHEBASISFORTHISSTUDYISAKNEEPROSTHESISDESIGNEDBYCHOW8THEPROSTHESISWASDESIGNEDONMECHANICATHEFILESWEREEXPORTEDINTOIGESFORMATWHENRETRIEVEDUSINGPRO/ENGINEERRELEASE15,THESURFACEMODELWASDISCONTIN
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