Rapid Prototype Blog

Archive for December, 2009

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It is often said that a sign of good worker is the tendency to plan before making any more regardless if it involves small or big tasks. This kind of thing becomes even truer in the case of people who deal in manufacturing of materials.

Rapid Prototyping is the term used to denote a set of techniques used in creating a scale model of a part of a machine with the help of CAD data. It makes use of several techniques such as Stereolithography considered to be the first Rapid Prototyping process, Selective Laser Sintering which is considered to be stronger than Stereolithography and can be used on a variety of materials, the relatively cheap Laminated Object Manufacturing although not as common as Stereolithography and Selective Laser Sintering, Fused Deposition Modeling which can be used with standard engineering thermoplastics, Solid Ground Curing that takes away the need for post-cure, and Inkjet printing techniques.

Regardless of which technique is in use, rapid prototyping follows a number of common basic steps, the first of which is to convert a CAD model into an STL format. Once this has been done, and the resolution set, the rapid prototyping machine makes sliced layers of the model. Afterwards, the first layer of the model is created and is lowered by the thickness of the succeeding layers. One this has been done, the model and the supports are removed and the surface is given some finishing touches.

This procedural model of how rapid prototyping work is actually the same mode being used in rapid tooling. In rapid tooling, the RP model is used either in quickly creating mold or as a way to fabricate the tool in a short span of time. RT can come in the form of Silicone Rubber Molding, Composite Molding and Direct AIM, among others.

In Silicone Rubber Molding technique, the mold fabrication time usually lasts for 15 days. If you want to go faster than that, you might opt to go for the RTV silicone rubber molding process. This is the last expensive rapid tooling technique and could give you about a dozen prototype parts in one mold. On the other hand, composite molding takes about 6 weeks but could produce up to 500 parts in one mold. They are usually cheaper and have a lower lead time than aluminum tools. Lastly, Direct AIM takes about two week for the fabrication process to finish, producing about 10 parts each day for each of the cavity.

Today’s market offers a variety of technologies to enable the rapid prototyping rapid tooling included, of parts. The differences in these technologies lie in the way layers are made in order to create the parts.

Rapid Sheet Metal™, Inc. hosted over 70 members of the New Hampshire Solidworks User Group (NH SWUG) on Tuesday, December 2.  After tours of Rapid’s state of the art sheet metal facility dedicated to the ultrafast turnaround of prototype sheet metal parts and a bountiful buffet dinner, the crowd settled in for an evening of discussions on cyber metal bending in the world’s most widely used sheet metal design CAD software, Solidworks.

 

Jay Patterson, Product Definition Specialist for SolidWorks, reviewed the tools and methodologies of how to design sheet metal parts within Solidworks.  Covering the basics as well as expert tips and tricks, Jay demonstrated the power of Solidworks for designing sheet metal.  Steve Lynch, Engineering Manager for Rapid Sheet Metal, followed with a presentation on manufacturing considerations for sheet metal design.  The audience was shown how a sheet metal shop uses their 3D Solidworks data to make real parts and the impact on manufacturing of certain CAD design features such as bend radii, hemming, offset bends and hardware insertion.  Concluding the meeting was a Question and Answer session that many felt had to end too soon. 

 

The User Group meeting was a great way for Solidworks Users to connect with others in the engineering community and refine their sheet metal design skills.  “Steve Lynch provided one of the best presentations we have ever seen.  Overall, everyone got a lot out of the night and I would consider it our best NH-SWUG meeting yet!  Kudos to Rapid Sheet Metal.” commented Cindy Berend, NH-SWUG President.

I am holding a lecture on Rapid Prototyping soon and I would like to open it with a childrens’ story on how something somebody imagined becomes real.
Rapid Prototyping is about having computer models conveniently made by machines, so you “dream it up” on screen, “flick a switch”, and bzzztt – here’s your dream object, miraculously become reality.
I’m looking for a nice story to relate to that. Is there anything?
Thanks.

Electrical circuit created by laying (printing) ‘tracks’ of a conductor such as copper on one or both sides of an insulating board. The Printed circuit board was invented in 1936 by Austrian scientist Paul Eisler, and was first used on a large scale in 1948.

A PCB is the acronym for Printed Circuit Boards, which are cards or circuit boards that are composed of a very thin flat metal or hard plastic-type board called an insulator. It is upon this that computer silicon chips and other similar electronic components are mounted. These boards are then used in electronic appliances like televisions, computers, washing machines, digital cameras, and so forth.

Components such as integrated circuits (chips), resistors, and capacitors can be soldered to the surface of the board (surface-mounted) or, more commonly, attached by inserting their connecting pins or wires into holes drilled in the board. The increased component density and complexity required by the electronics industry demands increasing use of multilayer PCBs which may have three, four, or more intermediate layers of copper conductor. PCBs include motherboards, expansion boards, and adaptors.

A PCB prototype is the first circuit board that is invented for a new electronic device. By using this prototype in the electronic device, the inventor can see if the prototype serves its purpose in the invention. Once the electronic device is made to function with the prototype, any mistakes that take place can be rectified in the prototype. In this way, the PCB prototype saves the inventor of the electronic appliance lots of money, as any mistakes that may be present in the PCB will be pinpointed before the actual commercial manufacture of the PCB.

Without having a prototype, the model of a new invention will be of no use if its board is not in good condition and up to requirements. Electronic appliances are getting more and more technologically advanced by the day. This advancement is done through changes on a prototype, which is then tried on the appliance to see if the advancement is in right order. Using different materials of the boards also account for changes in the prototype. You can use fiberglass, Teflon or cross-linked polystyrene for the PCB, and it is through the prototype that you find out which material best fits your needs. Nowadays, new PCBs are in use in electronic appliances, thanks to the prototypes.

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