Rapid Prototyping (RP) enables the quick fabrication of physical models using three-dimensional computer aided design (CAD) data. Used in a wide range of industries, Rapid prototyping allows students to turn innovative ideas into successful end parts rapidly and efficiently.
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Rapid prototyping systems emerged in with the introduction of stereolithography technology, a process that solidifies layers of ultraviolet light-sensitive liquid polymer using laser technology. In subsequent years, other rapid prototyping technologies were introduced, such as: Fused Deposition Modeling (FDM), Selective Laser Sintering and Laminated Object Manufacturing. The industry's very first 3D rapid prototyping system based on FDM Technology was introduced in April, , by Stratasys. The first 3D rapid prototyping systems based on PolyJet technology were introduced by Objet in April, .
Rapid Prototyping, also known as 3D printing, is an additive manufacturing technology. The process begins with taking a virtual design from modeling or computer aided design (CAD) software. The 3D printing machine reads the data from the CAD drawing and lays down successive layers of liquid, powder, or sheet material ' building up the physical model from a series of cross sections. These layers, which correspond to the virtual cross section from the CAD model, are automatically joined together to create the final shape.
Rapid Prototyping uses a standard data interface, implemented as the STL file format, to translate from the CAD software to the 3D prototyping machine. The STL file approximates the shape of a part or assembly using triangular facets.
Typically, Rapid Prototyping systems can produce 3D models within a few hours. Yet, this can vary widely, depending on the type of machine being used and the size and number of models being produced.
FDM Technology uses production-grade thermoplastics for durable, usable parts that are thermally, chemically and mechanically tough.
PolyJet Technology jets liquid photopolymer in fine droplets and solidifies it with UV light, resulting in impressively smooth, detailed surfaces and the ability to print clear, flexible and rigid components in one job.
The good news for part designers and engineers is that there is a wide range of viable manufacturing processes available when it comes to online rapid prototyping services. While there are many different options when it comes to which rapid prototyping process to use, engineers must decide which process and material would be the best for their specific prototype. A growing trend in rapid prototyping is the use of 3D printing technologies because these methods are very affordable and offer short lead times.
When it comes to rapid prototyping, 3D printing is one of the most common and effective manufacturing methods. What makes 3D printing immensely popular for rapid prototyping is that it's cost-effective and fast.
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Here is a closer look at the three most common 3D printing methods used for rapid prototyping: selective laser sintering (SLS), stereolithography (SLA), and fused deposition modeling (FDM).
CNC machining processes including turning and milling are excellent for rapid prototyping when parts need a prototype to be analyzed in its final material if cut from fully dense stock. Additionally, a wide range of plastics and metals can be used in rapid CNC machining.
When it comes to lead time, CNC machined prototypes can often be manufactured and distributed in less than a week. Despite this speed, 3D printed prototypes are still produced faster than CNC machined prototypes because of the extra machine set-up time required in CNC machining.
Rapid sheet metal fabrication is commonly utilized when producing quick-turn flat parts that need a prototype to be analyzed using the production metal material. These types of parts are turned around in one week or less. Moreover, rapid prototyping using sheet metal fabrication is so cost-effective that you can often fabricate two or more prototype designs in parallel.
While the most common sheet metal used in rapid prototyping is Aluminum , there are also several different types of alloys that can be used including stainless steel, copper, and steel. While rapid sheet metal manufacturing offers lead times that are comparable to rapid CNC machined parts, the lead times are longer than 3D printed prototypes. Additionally, it's important to keep in mind that sheet metal fabrication involves additional set-up time like CNC machining, whereas 3D printing does not.
Rapid injection molding has the ability to produce highly durable sets of identical prototypes for testing purposes. Using plastic material, rapid injection molding offers both bridge tooling during product launches and also high-fidelity part evaluations.
Generally speaking, the lead time for rapid tooling with injection molding is two weeks for the initial parts. In many respects, rapid injection molding is the best solution for rapid prototyping compared to CNC machining or 3D printing because of stringent mechanical demands and material requirements that are oftentimes mandatory in those processes.
There's no denying that rapid plastic injection molding is slower compared to CNC machining and 3D printing, but this shortcoming is compensated by its ability to produce prototypes in as close to the intended geometries as possible. In this sense, injection molding leads the way because of its ability to achieve superior repeatability and extremely accurate final forms.
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