The study of rapid prototyping process with embedded functional inserts

The purpose of this paper is to study the process of making functional inserts embedded rapid prototyping (RP) parts. A generalized procedure and its associated insert classification method for easy inserting functional parts into a RP product on-line are proposed. The inner product of two vectors, the mock-up construction direction and the surface normal vector of the insert, are taken as the criterion of implementation. Based on this method, most of the axis-symmetric functional inserts are classified into three groups according to their shapes and orientations in the RP part, namely if they can be inserted directly, a simple shape converter is needed, or a multiple shape converter is needed. The shape converter is manufactured in advance if it is required. The shape converter is assembled with the insert, and the whole unit is then placed into the frame. Thereafter, laminating process is proceeded until a complete RP part is finished without any interference. The proposed procedure and insert classification method are verified via the new on-line de-cubing laminated object manufacturing (LOM) process. Three cases studies were considered and experiments were conducted. Results show that the RP parts with insert or functional insert are made successfully.