Course detail

Polymer Prototypes and Rapid Prototyping

FSI-ZPPAcad. year: 2014/2015

Plastics are the most versatile material widely used in all sectors from the packaging industry, civil engineering, till automotive, aerospace and healthcare. Design of plastic parts is closely associated with production technology and knowledge in the design of plastic parts and are highly prized in practice. Students will learn about the basic chemical nature and structural properties of polymer materials, plastic injection molding technology and design principles for the design of injection molds, vacuum molding technology of plastics, vacuum casting into silicon molds and with additive manufacturing technologies (Rapid prototyping).
The course has been upgraded with the support of the OPVK project. Project "The Studio of digital sculpture and new media", reg. No. CZ.1.07/2.2.00/28.0278, is co-financed by the European Social Fund and the statebudget of the Czech Republic.

Language of instruction

Czech

Number of ECTS credits

5

Mode of study

Not applicable.

Guarantor

prof. Ing. Ivan Křupka, Ph.D.

Department

Institute of Machine and Industrial Design (ÚK)

Learning outcomes of the course unit

Students will learn about the properties and the suitability of the engineering polymeric materials. They will gain knowledge of injection molding technology and design principles for the design of injection molds. They become familiar with the technology of vacuum forming of plastics, technology of vacuum casting into silicon molds and additive manufacturing technologies (Rapid prototyping). Acquired knowledge will enable them to design products from plastic materials and effectively choose the production technology of the prototype within the design phase of product development.

Prerequisites

Knowledge and experience of design with CAD (Inventor, Catia, Rhinoceros, Creo Parametric), knowledge of design principles for castings.

Co-requisites

Not applicable.

Planned learning activities and teaching methods

The course is taught through lectures explaining the basic principles and theory of the discipline. Teaching is suplemented by practical laboratory work.

Assesment methods and criteria linked to learning outcomes

Graded course-unit credit is awarded on the following conditions: active participation in the seminars. Knowledge of principles of discussed technologies, including problems and limitations in their applications. Furthermore, it is necessary to prove knowledge by submitting manufactured prototype without serious deficiencies. Another evaluation criterion is written examination of theoretical knowledge, focused on essence of discussed problems, their solution and applications.

Course curriculum

Not applicable.

Work placements

Not applicable.

Aims

The aim of the course is to provide theoretical and practical experience in the design and manufacture of plastic parts and prototypes. Students become familiar with the technologies of serial and prototype production of plastic parts and with the design and technological limitations and design procedures that are required by different technologies.

Specification of controlled education, way of implementation and compensation for absences

Attendance at lectures is recommended; attendance at laboratory practicals is obligatory and checked by the lecturer. Compensation of missed lessons depends on the instructions of course supervisor.

Recommended optional programme components

Not applicable.

Prerequisites and corequisites

Not applicable.

Basic literature

Zeman, Lubomír, Vstřikování plastů, BEN 2009, 978-80-7300-250-3 (CS)
Zeman, Lubomír, Vstřikování plastů, BEN 2009, 978-80-7300-250-3 (CS)
Throne, James L., Understanding thermoforming, Hanser Verlag 2008, 978-1-56990-428-2 (EN)
Throne, James L., Understanding thermoforming, Hanser Verlag 2008, 978-1-56990-428-2 (EN)
Sias, F. R. , Lost-wax casting, Woodsmere Press 2005, 0-9679600-0-2 (EN)
Sias, F. R. , Lost-wax casting, Woodsmere Press 2005, 0-9679600-0-2 (EN)
Řehulka Z, Konstrukce výlisků z plastů a forem pro zpracování plastů, Sekurkon 2006 (CS)
Řehulka Z, Základní a technické polymery, Sekurkon 2006 (CS)

Recommended reading

Not applicable.

Classification of course in study plans

  • Programme M2I-P Master's

    branch M-KSI , 2. year of study, winter semester, compulsory

Type of course unit

 

Lecture

13 hours, optionally

Teacher / Lecturer

Ing. Jiří Gabriel
doc. Ing. Daniel Koutný, Ph.D.
Mgr. František Kučera, Ph.D.

Syllabus

1.- 3. Polymeric materials, classification, chemical nature, production of polymers, transition temperatures, properties and behavior, rheology, degradation.
4.- 6. Plastic component design, gating systems.
7.- 8. Principles of design of plastic parts, moulds cooling.
9.- 10. Mechanical systems of injection moulds, moulds venting, examples of moulds design.
11.- 12. Basic information about rapid prototyping, summary of RP methods, resources (programs and data) of RP, utilization RP methods.
13. Excursion with the presentation of RP technologies Polyjet, LOM and FDM for mass production and large parts.

labs and studios

26 hours, compulsory

Teacher / Lecturer

doc. Ing. Daniel Koutný, Ph.D.
Ing. Radek Vrána, Ph.D.

Syllabus

1. Rapid prototyping, Fused Deposition Modeling (FDM)
2. Rapid prototyping, Three-Dimensional Printing (3DP)
3. Rapid prototyping, Selective Laser Melting (SLM)
4. Vacuum forming of plastics, Formech laboratory machine.
5. CNC machining of mastermodels, milling with CharlyRobot 2U, robotic machining of molds.

Vacuum casting of plastics into silicone molds.
6. Safety in the laboratory, control vacuum furnace MK Technology - System 1 .
7. Technological principles for the production of silicone molds, parting plane, cutted form.
8. Preparation of mastermodel, creating a frame for silicone mold.
9. Production of the first half silicone mold, gate system.
10. Production of the second half of the mold, venting of the form.
11. Tempering of the mold, casting of prototype.
12. - 13. Working in groups on assigned prototypes.