Abstract
In this work, two complex-shaped products have been reverse engineered through rapid prototyping (RP). First product is a single unit with a number of complex features while the second product has sub-parts to be assembled together. These sub-parts have various complexities. One sub-part will frequently be in motion. Target points are set on complex features of the scanned 3D point data to measure deviations of generated surface models from scanned data and subsequently from physical models. Two layer-by-layer manufacturing systems, i.e. one employing ceramic powder-based 3D printing and other fused deposition method have been used to develop RP models of complex shapes. Suitability of the process for complex-shaped prototypes has been discussed and recommendations have been made for parameter settings and suitable process. Moreover, economic analysis has also been performed with an objective to minimize the development time and cost.
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