7-FEB-2022

What is Rapid Prototyping?

Rapid prototyping is the production of a physical object, either a model or total assembly using CAD (computer aided design) The creation of the part, model or assembly is usually created using additive manufacturing, or more commonly known as 3D printing. Where in the past this would have been done by machining (CNC) Depending on the maturity of the model the finished part can be very close to the production version.

How Does Rapid Prototyping Work?

Rapid prototyping includes a variety of manufacturing technologies, the most utilized, as well as the method used by us here at Custom 3D prototype is layered additive manufacturing. Other technologies used for rapid prototyping include high-speed machining, casting/molding and extruding. Should your project require one of these methods we can also help facilitate getting you your part via one of our partners.

What are the Different Types of Rapid Prototyping?

Stereolithography (SLA) or Vat Photopolymerization

This is the oldest technique and was the first successful method of commercial 3D printing. It uses a bath of liquid that responds to light which is solidified layer-by-layer using a computer-controlled ultra violet (UV) light.

Selective Laser Sintering (SLS) and Selective Laser Melting (SLM)

Unique in that SLS can be used both metal and plastic prototyping, SLS uses a bed of powder to build a prototype one layer at a time using a laser to sinter the powdered material into a solid. However, the strength of the parts is not as good as with SLA, while the surface of the finished product is usually rough and may require secondary work to finish it. The newer version is SLM this process is favored for making high-strength more complex parts than available by SLS. Selective Laser Melting is frequently used by the aerospace, automotive, defense and medical industries.

Digital Light Processing (DLP)

Similar to SLA, this technique also uses the (light sensitive) polymerisation (Which is a chemical reaction where monomer molecules join together to form polymer chains or three-dimensional networks) process for resins which are cured using a more conventional light source than with SLA. While faster and cheaper than SLA, DLP often requires the use of support structures and post-build curing.

An alternative version of this is Continuous Liquid Interface Production (CLIP), whereby the part is continuously pulled vertically from a vat, without the use of layers. As the part is pulled from the vat it crosses a light barrier that is used to create the desired cross-sectional pattern on the plastic.

 

Fused Deposition Modelling (FDM) or Material Jetting

This cost effective, easy-to-use process can be found in most non-industrial desktop 3D printers. It uses a spool of thermoplastic filament which is melted inside a special heated nozzle barrel. The resulting process is a liquid plastic that is laid down layer-by-layer according to a computer deposition program. This process is has vastly improved in the past decade and is very fast and inexpensive, this makes it the most useful RP method especially in quick turn iterative design work and the method preferred by Custom 3D Prototypes.  

What are the Advantages?

Given all of the various methods there are a number of rapid prototyping advantages The ability to gain a more complete picture of how a product will look or function in the early stage of the design cycle, allowing changes and improvements to be into place much earlier in the overall process. Sometimes this can even be done in a few days rather than a few months.  

Overall RP is a very cost effective way to prototype products as it is an semi-automated process, requiring less hands on development. This process is also extremely accurate. Simply being able to use the exact customer model and utilizing the power of computer aided design (CAD) to help reduce the amount of material wastage without the need for special tools for prototyping each new product or product iteration. Being able to act quickly and solve any problems will reduce the downstream risk of costly errors that may otherwise come up during the manufacturing of the part.

Rapid Prototyping helps designers present new concepts to board members, clients or investors so that they can understand and approve a development or product. The ability to take the exact part or even a scale model of the part allows the end user to visualize the final product in a way that is not possible with PowerPoint or a screen shot. This visualization can also allow the engineer or designer to get instant feedback from customers and clients based on the physical product rather than a idea.

Rapid Prototyping Services

Custom 3D Prototypes has many years of experience and expertise in 3D printing technologies and additive manufacturing processes. We can also assist with your rapid prototyping technology and manufacturing process development even if we don’t produce your parts. We can supply some prototype examples