Rapid Prototype Blog

Posts Tagged ‘Invention’

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 PCBs are then used in electronic appliances like televisions, computers, washing machines, digital cameras, and so forth.

A prototype can be considered the first working model of an invention. So in this case, a PCB prototype is the first circuit board that is invented for a new electronic device. By using this PCB 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 PCB 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 PCB prototype, the model of a new invention will be of no use if its PCB 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 PCB prototype, which is then tried on the appliance to see if the advancement is in right order. Using different materials of the PCB also account for changes in the PCB prototype. You can use fiberglass, Teflon or cross-linked polystyrene for the PCB, and it is through the PCB prototype that you find out which PCB material best fits your PCB. Nowadays, new PCBs are in use in electronic appliances, thanks to the PCB prototypes.

Prototypes provides detailed information on Prototypes, Prototype Makers, Pcb Prototypes, Car Prototypes and more. Prototypes is affiliated with Invention Patents.

Method of integrating wear plates into a spray formed rapid tool includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one wear plate on the ceramic pattern and thermally spraying a metal material against the wear plate and ceramic pattern to form the desired tool and embedding the wear plate into the desired tool.

It is known to make a spray formed rapid tool. In spray forming, a master model of a desired tool is produced using a free form fabrication technique. This master model is then used to create a ceramic pattern which is the reverse of the desired tool to be produced. The resulting ceramic pattern is the receptor onto which metal is sprayed to form a deposit in the shape of the desired tool.

Typically, the spray forming process uses a wire-arc spraying. In wire-arc spraying, electric current is carried by two electrically conductive, consumable wires with an electric arc forming between the wire tips. A high-velocity gas jet blowing from behind the consumable wires strips away the molten metal which continuously forms as the wires are melted by the electric arc. The high-velocity gas jet breaks up or atomizes the molten metal into finer particles in order to create a fine distribution of molten metal droplets. The atomizing gas then accelerates the droplets away from the wire tips to the ceramic pattern where the molten metal droplets impact the ceramic pattern to incrementally form a deposit in the shape of the desired tool. The completed desired tool is then mounted and used to produce parts in conventional stamping, die casting, or molding processes.

Molds may be used for injection molding parts. The mold may include one or more slides for forming a particular feature of the molded part. Mold slides are common features in complex injection mold or die cast tools where undercuts are designed into the molded part. Mold slides are used to allow the molded part to be ejected from the mold without interfering or being trapped by the molding features which create the undercut in the molded parts.

Wear plates are typically provided in conventional molds to provide a hard, but machinable smooth bearing surface for the slides to run or ride on. The wear plate is positioned to guide the slide where it needs to go in the mold. Wear plates ease repairability of a mold and increase its life.

The spray formed rapid tool may be used in molds for injection molding parts. The spray formed rapid tool may be used with mold slides. Currently, wear plates for spray formed rapid tools are machined into the spray formed rapid tool after the spray process is completed. Although the wear plates machined into the spray formed rapid tool have worked well, they suffer from the disadvantage that the machining process is both laborious and time consuming. Another disadvantage is the thermal spray coatings are heavily oxidized and the wear plates can only be ground or electro discharge machined (EDM) into the spray formed rapid tool which is costly. Yet another disadvantage is that the high oxide content does not allow for weld repair or traditional machining processes on the wear plates of the spray formed rapid tool.

Accordingly, the present invention is a method of integrating wear plates into a spray formed rapid tool. The method includes the steps of making a model of a desired tool and constructing a ceramic pattern as the inverse of the model. The method also includes the steps of locating at least one wear plate on the ceramic pattern. The method further includes the steps of thermally spraying a metal material against the wear plate and ceramic pattern to form the desired tool and embedding the wear plate into the desired tool.

One advantage of the present invention is that a method is provided of integrating prefabricated cast or wrought wear plates into a spray formed rapid tool at the same time the spray material is being deposited. Another advantage of the present invention is that the integration of wear plates in a spray formed rapid tool shortens product development cycle time. Yet another advantage of the present invention is that the wear plate can be machined or modified after the spray formed deposit is completed.

Still another advantage of the present invention is that the wear plate can be conventionally machined to make it parallel to the surface of the slide. A further advantage of the present invention is that the wear plate can be conventionally machined instead of using the EDM process, thereby saving time and cost. Yet, a further advantage of the present invention is that the method eliminates secondary machining of the thermal spray material. Still a further advantage of the present invention is that the method reduces material loss. Another advantage of the present invention is that the method improves yield, quality and repeatability.

Once the spray formed rapid tool is formed, the ceramic pattern is removed by chipping, grit blasting, or using a water jet. The slide contact surface can be machined “true” to the rest of the spray formed rapid tool after the spray process is complete if the wear plate 16 was not in the exact location during the spray deposition.

The present invention relates generally to wind tunnel models. More particularly, the present invention is directed to a wind tunnel model design using rapid prototype components and a reinforcing strongback. Whether an airframe is a new design, modification of an existing design, or evaluation of a competing or foreign design, an accurate, high-confidence representation of the airframe aerodynamics is paramount to any low-risk design or evaluation effort. These aerodynamic estimates are used for vehicle and component sizing, performance estimates, and autopilot design and evaluation. The only accepted method of obtaining the high fidelity aerodynamics data needed for these purposes is to build and test a scale model of the airframe in a wind tunnel. Most wind tunnel models are fabricated of all metal components using Computerized Numerical Control (CNC) milling machines. The dimensional accuracy, surface finish and strength of such all-metal models have a distinguished history of providing high fidelity aerodynamics data for both subsonic and supersonic aircraft and rocket designs. However, the fabrication of all-metal wind tunnel models is very expensive and time consuming. Following is a brief summary of the wind tunnel model construction process and of prior art attempts at reducing the costs and time invested in such models. A typical aircraft development program usually needs at least four to five wind tunnel models to adequately test the aerodynamics of a new airframe. The models are generally made of aluminum (for lightly stressed components) or steel (for highly stressed components) and are sculpted using 3 to 5 axis CNC milling machines. The models can require months to manufacture and are often made by small high technology companies that specialize in wind tunnel model manufacture. Wind tunnel models are generally supported in a wind tunnel by a positioning device that is often referred to as a sting. The rear portion of a model is usually hollow to allow the sting to penetrate the model body without affecting the aerodynamic properties of the model. A force transducer called a balance is attached to the inside of the model in order to measure forces and moments acting on the model (often measuring all six degrees of freedom: drag, sideforce, lift, roll, pitch and yaw). The sting is rigidly fixed to the balance and all lead wires from the balance and any other control lines or strain gage leads from the model are routed inside or along the sting and back to the control room of the wind tunnel facility. The cost of fabricating and instrumenting a typical wind tunnel model is on the order of 0,000; however, complex models that include engine simulators, remote controlled control surfaces, numerous rows of pressure taps, etc., can cost over ,000,000. Companies that are able to reduce the time and costs associated with wind tunnel models therefore stand to gain a significant competitive advantage. For several years Rapid Prototype (RP) materials and methods have been considered as a potential source of improvements to conventional wind tunnel models. RP parts can generally be made much more rapidly and less expensively than conventional machined parts. RP manufacturing is a field of high technology concerning the generation of three-dimensional solids using particles or layers of mostly polymeric materials. Two of the most popular RP techniques include stereolithography (SLA.RTM.) and fused deposition modeling (FDM.RTM.). Both techniques build solid objects layer-by-layer based on data from a computer aided design (CAD) software program. SLA.RTM. equipment is manufactured by 3D Systems, Inc. of Valencia Calif. and employs a laser beam to selectively solidify the surface layer of a photopolymer resin. The solidified surface layer forms a cross section of the prototype part. A supporting table then lowers the part several thousandths of an inch into the resin and the laser solidifies the next layer. These and other objects are achieved in the present invention in a wind tunnel model including a strongback, made of a rigid material and having an exterior axial surface, the strongback being designed to be supported by a balance. The strongback is at least partially inside the interior volume of a jacket section that is made of a rapid prototype (RP) material. The exterior axial surface of the strongback engages an interior axial surface of the jacket section, and the exterior surface of the jacket section defines at least part of an aerodynamic surface. The techniques of the present invention are applicable to any wind tunnel model design intended for use with a balance for measuring forces and moments applied to the model. This includes aircraft such as planes, rockets and missiles as well as ground based vehicles such as high-speed racecars. Other objects and advantages of the invention will become more fully apparent from the following more detailed description and the appended drawings that illustrate in detail one embodiment of the invention. In the following description, all like reference numerals refer to like elements.

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The prototype or model as a discovery tool

Getting from the “invention residing in your brain”, to an actual functioning product is called “reducing the invention to practice”, and almost invariably leads to the discovery of a number of problems with details that are not clearly evident when only residing in your mind.

Producing a model will help you find the best way to manufacture the device you have invented. It can be useful for all sorts of things like figuring out where to put labels, what the shipping weight will be, how to best package it, what it might cost to manufacture it, and to get feedback from test users. It’s a valuable tool for you to use.

An invention prototype can help you raise money

People just don’t have much imagination.  You are an inventor, and so you do have an imagination. Before you can invent something you have to have the idea…and it takes imagination to come up with great new ideas. Other people, you will find, simply do not have the imagination or vision that you do. Help them out.

With a good invention prototype or model, your audience will not need to have an imagination.  It makes the invention “real” for them, adding tremendously to your credibility.  Having a good invention prototype will help sell the product even if it is not even in production yet. 

Prototype your invention before you file for a patent

DON’T put off prototype building until after you file your patent application. You will probably discover flaws or new features, or discover possible manufacturing problems.  With rare exception prototyping is very worthwhile. There are almost always unexpected discoveries from construction of invention models and prototypes.

Prototype for invention for testing purposes

Testing is very important.  A prototype allows you to actually test your invention in a meaningful way. You can test it with people other than yourself if appropriate, and you will probably discover that other people will have constructive criticisms and suggestions that could be very valuable.

By searching online you can find model and prototype building companies who can build it for you if you do not have the skills yourself.

Sure there are times when a prototype is not practical, if it is too expensive for example, but if it is at all possible, I highly recommend an invention prototype or model be produced.

I’ll make some prototypes, show/give them to friends and to people I believe to be the ‘market’, and usually get positive feedback. But I feel they’re just being polite or don’t want to offend me with a negative critique. Further advice on bringing a gadget to production, to market would be greatly appreciated.

I’ve patented 2 on my own but ran out of money before marketing and perfecting final design. I don’t want to go through any ‘invention to market’ businesses you here about on radio/tv.