Rapid Prototype Blog

Posts Tagged ‘Innovation’

TJ Hendrickson’s ‘Introduction to Engineering Design’ class discusses their projects and the Dimension 3D Printer they used to bring their creations to life. After using college-level mathematics to design their models in CAD software, printing is as easy as clicking “print” and their file is built on their Dimension 3D Printer. Source: Shakopee Valley News – 4/23/09 www.shakopeenews.com

The 3D Printer or rapid prototyping system is a computer assisted manufacturing process where software guides the creation of three dimensional models. In the past model makers had to rely on plastic formers or metal modeling techniques to create replicas, reproductions and prototypes. But now because of the more advanced technologies that have been developed in the area of prototyping a new process known as rapid prototyping manufacturing is available. The 3D printer technology available today allows the hobbyist to create custom designed 3 dimension models simply and easily in the comfort of their own workshop. Long and timely manufacturing processes have been eliminated by the 3D printer and at a reasonable price for the hobbyist.

3D Printer Technology and Model Creation

Traditional modeling techniques available to the hobbyist involved a long list of design steps and an even longer list of manufacturing steps. Imagine having a 3D printer that could reproduce from a computer assisted design (CAD) file a rare model train to add to your collection. The 3D printer would build the model train from the ground up with all the features of the original including the lettering and the correct color of paint. Using liquid polymers extruded from injectors the 3D printer would craft a replica of the train that would be indistinguishable from the original design. By building the train layer upon layer the 3D printer software would calculate the proper length, width and height requirements from the specifications and the rapid prototyping process would produce a completed 3 dimensional model of the train. The 3D printer technology would enhance any hobbyist’s abilities and creativity.

3D Printer Advantages for Model Reproduction

The computer assisted design advantages of the 3D printer are numerous compared to traditional prototyping techniques. Traditional techniques that employed plastic formers to create models required large, bulky and sophisticated equipment which also required a major investment to own and operate. 3D printers however are reasonably sized, compact and much less expensive to own and operate. The set up time and ease of operation has made the 3D printer a popular choice for creating models and replicas. The almost unlimited flexibility and potential applications for the hobbyist to create models with the 3D printer is a distinct advantage of this technology.

Traditional modeling techniques carried some dangers inherent in the process. Some techniques involved hot metals being poured into molds while others heated toxic chemicals which were pressurized and cooled. The technology used in the 3D printer produces no toxic chemicals to harm the hobbyist nor uses any toxins during the prototyping process.

With metal modeling techniques a substantial amount of post production cleanup of the models and work area was needed. With the 3D printer an additional advantage is gained from using the rapid prototyping technology as post production work is drastically reduced. The advantages of the 3D printer for the hobbyist are many including creative flexibility, safety and ease of operation. The innovative designs that the hobbyist will be able to utilize with the 3D printer present a distinct advantage over traditional model and replica processing methods.

3D printing also known as rapid prototyping technology is the design process where computer programming guides the creation of a three dimensional model through the layering of fabrication material. Engineers, designers and technicians would benefit from advanced prototype production. Recently new technologies have been developed producing many advantages for those needing rapid prototype technology. The 3D printers available today are faster, easier and more affordable than previous fabrication technologies. 3D printing has also eliminated the need for expensive tools and skilled craftsmen to produce design prototypes, making the process more affordable, cost efficient and desirable.

3D Printer Technology

The 3D printers technology is quite simple to understand really; computer assisted design software (CAD) directs an inkjet nozzle to extrude small amounts of material in layers to form a three dimensional model. Almost like building a sand castle at the beach. By adding layer upon layer the CAD software is able to calculate length, width and height requirements from design specifications and guide the process toward completion of a 3 dimensional model. Traditional prototypes were built from solid blocks of material and the excess was cut away until the model was produced but with today’s technology the models are built from the ground up with no excess. Of course the sophistication of designs and materials used will impact the time required to produce individual 3D prototypes.

Individual 3D printing needs will differ and so the materials used in prototyping will differ also. In rapid prototyping the materials used can range from plasters, resins and advanced polymers. The choice of design material depends on the required durability, lifespan or sophistication level of the model to be fabricated. Fused deposition modeling techniques use liquid polymers from injectors to create models. In this process the 3D Printer injects photopolymers layer by layer on to a base platform and then the materials are cured with ultraviolet light. Inkjet printing techniques differ as they use granular substances such as plaster, powder or corn starch and combine the materials with an adhesive which bonds the model together to produce a 3D prototype.

3D Printer Advantages

The new technology of 3D printing produces advantages in the areas of speed, cost, and simplicity. Engineers and design technicians can use 3D printing during the conceptual stages of design. A rapid prototype enhances the design process by providing a 3 dimensional model of the design. Having an actual model to see and manipulate during various stages of the design process can help designers and engineers to facilitate prototype corrections, enhancements and project completion.

Also, unlike some prototyping techniques the 3D printing advantage produces no toxic chemicals from the process nor uses any toxins during the process. An additional advantage gained from using rapid prototyping technology is post production work is minimal, only the removal of excess materials produced during the printing process is necessary. The advantages of 3D printing are many including reduced costs, efficiency and safety. As new innovations in 3D printing technology become available so will additional advantages.