A novel rapid prototyping system for expandable polystyrene

Abstract

PurposeExpanded polystyrene (EPS) is a low‐density and cheap material, which has been widely used in commercial areas. As the demand for small‐batch, flexible and quick production increases, producing EPS products with metals moulds has become unaffordable. The purpose of this paper is to describe the development of an EPS rapid prototyping (ERP) process, with an electric heating tool.Design/methodology/approachTwo new cutting strategies for the ERP process, constant angle mode and constant thickness mode, are proposed. The methods to generate tool path of those models are also discussed. In order to improve accuracy and cutting effectiveness, experiments have been carried out to investigate the thermal characteristics in the ERP process. Consequently, the relationships between the size of material removal area and process parameters are obtained. Suitable processing parameters for the ERP system are also conducted.FindingsIt is found that the ERP process can rapidly produce complex three‐dimensional parts in one‐off clamping without post‐processing procedures as in traditional rapid prototyping, such as, extra support removing, step texture finishing and distortion regulating.Originality/valueThe paper provides several examples to explain and illustrate the applicability and workflow of the ERP system.