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Posts Tagged ‘Prototype’

This technology is also used by the sculptors in order to achieve complicated shapes for display in any exhibition of fine arts. Rapid prototype creates 3D models with the help of virtual designs from animation modeling software or computer-aided design, which helps in transforming the design into thin layers, virtual and horizontal cross sections until the entire model is complete and all these can be done with the help of additive manufacturing technology present in rapid prototyping. With the use of this particular technology the virtual image can be easily transformed into the physical model.

• The additive manufacturing technology helps the machine to read data from computer aided design and builds the model with the help of layers of liquid, powder and sheet material. Various cross sections are used while building up the model. The layers are combined with the virtual cross section automatically to get the final shape.

• The biggest advantage of the rapid prototype fabrication is that it is able to form or create any type of geometric feature or shape.

• The stereo lithography helps in the plastic mould formation of the accurate shape of any object with the usage of triangular facets and aims at quality production.

• The models can be constructed within hours instead of days. The time depends on the complexity of the object to be created or the type of machine used. It definitely takes lesser time than the usual digital data or 3D.

• The technique of solid freeform fabrication uses two types of materials, the part material and the support material, which is later removed with a solvent, by water or by heat.

• There are 3D printers present in the rapid prototype machine that helps the manufacturers or the designers in the rapid development of the production.

• It helps the manufacturers by detecting the flaws and errors beforehand and thereby reduces the cost of re-work. It gives the right and clear concept of the idea and plan that is supposed to be implemented by the manufacturers.

• Rapid prototype helps in the construction of the prototype at a very low cost in a very short period of time. The plastic mold is almost similar to the actual product and it is created by the cross sections and forming layers in the free space until the model is prepared.

• It is beneficial for the implementation of new ideas and plans for the manufacturers and used in a short production cycle, where the time is very limited and the task is to be finished at a low capital investment.

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I will give some advice about avoiding costly mistakes while running sample product and PCB assembly and how to minimize time to market for new electronic products.

Making of prototypes is the first step of a new product launch and is typically done following simulation of product performance by employing the simulation capabilities of PCB and industrial design software. The simulation results often allow you to find errors and help you improve your design. This will save time and money by minimizing the amount of prototype iterations required before mass production.

One strategy to speed up sample optimization is working with a modular design. A modular design will concentrate core features of your design in particular parts which are interchangeable. Throughout your sample optimization you can then improve separate modules that do not yet meet your performance constraints rather than having to rebuild your entire design. When a specific module does not meet the design constraint, it can be swapped relatively quickly. The time benefit at this stage is evident. During the design phase though structuring your design into modules will take additional effort.

Depending on the design complexity, you might consider manually mounting PCB components to reduce cost. Then again, for average to large complexity this approach tends to be exceptionally time consuming, particularly if you want to build a number of prototypes. Thus it makes sense taking into consideration a contract manufacturer for the assembly.

You ought to look for a subcontractor that has a low setup cost since this cost is going to dominate the total expense in case of small-quantity runs. Because prototype PCB vendors combine boards from several customers, you will typically only have a limited selection of board materials and thicknesses when employing a PCB prototyping service.

Try to choose a manufacturer that not only has low setup costs but also can do full-quantity assembly runs. Specialized prototype assemblers might not be equipped to take on larger quantity manufacturing. This has the advantage of simplifying the migration between sample and finished product. Your supplier may then very easily reuse your translated design files. This may not be the case if you are switching suppliers. Also, chances are that your new supplier will read some files differently which will risk performance of the finished product.

A number of PCB vendors also can aid you throughout the design by offering in-house PCB design. If you are not very experienced in the design, you may want to think about choosing such a vendor. Such a vendor can also much more simply and much more rapidly solve design-related issues.

Buying components for prototype runs is a concern. Purchasing components in small quantities is expensive and involves a lot of work. Also, a number of suppliers have minimum order quantity requirements. Small quantities of SMT parts are hard to mount by automatic machines because they normally do not come in reels. If you select a supplier that has stock of commonly used SMT parts which you can order, you can save a lot of time. In addition, you won’t waste any parts which are left over.

If you picked a manufacturer that also does the final product assembly, you will not only save time to market but also ensure that circuit boards that are found to be faulty during the final examination will be repaired much more rapidly. Be sure you can easily and effectively converse with your supplier. Also, make certain that your supplier can identify with your issues. This ability will be key in avoiding expensive delays and errors of the PCB assembly and final product manufacturing.

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For people outside the fields of engineering and technology, there can be some confusion regarding the terms “3D printers” and “rapid prototype machines.” This conundrum is to be expected since there are even engineers who are not aware that these machines exist.

Nonetheless, both these machines are used in fabricating scale models used in engineering, automation, manufacturing and mechanics. In recent years, however, the use of these machines has expanded beyond the confines of engineering to medicine, education, and even the arts. But what makes these machines different from each other?

What Are Rapid Prototype Machines?

The term “rapid prototype machine” actually refers to a wide range of machines that use many different technologies to create scale models. These technologies have names such as stereolithography, where photosensitive resin is shaped and hardened by a laser beam; solid ground curing, where the resin is cured with ultraviolet rays; or fused deposition modeling, where melted polymer is built in layers around a support structure.

Regardless of the technology used in these machines, the procedure used in creating models is almost uniform. A model is generated using CAD software, and the model is then converted into a file with an STL extension. The rapid prototype machine then processes this STL file by slicing it layer by layer. These layers are then produced on a platform using resin, and once completed the model is finished and cured.

3D Printers Are Rapid Prototype Machines

As for 3D printers, they are actually a subclass of rapid prototype machines. What makes them distinct from the other rapid prototype machines is that they are faster. The word “rapid” in rapid prototype machines can be misleading because creating models with them can still take days, even weeks. With 3D printers, you can have your model within a matter of hours, even minutes.

Most machines that are classified as 3D printers make use of inkjet printing technology, which is why they are called “printers” in the first place. This does not mean that 3D printers use inkjet technologies exclusively. There are such machines that also use derivatives of the fused deposition modeling process or the ultraviolet curing process. In 3D printers that use inkjet technology, the resin is sprayed on the printing platform using inkjet nozzles.

Another characteristic of 3D printers is that the base materials they use are usually non-toxic and do not require curing or finishing. This is a big contrast with 3D models created with stereolithography, for instance. In stereolithography, the resins that operators work with can become toxic if left uncured.

In addition, 3D printers are a lot less expensive. A starter 3D printing machine can cost US,000. While that figure cannot be considered cheap, it is relatively inexpensive compared to high-end rapid prototyping machines that can cost hundreds of thousands of dollars. There are also 3D printing machines that you can make on your own using starter kits and open source software.

The method has a number of key distinctions: Unlike traditional, linear models of rapid prototype product development, it’s a cyclical process where one cycle inputs into the next and where a variety of solutions move repeatedly through a range of stages. It integrates rapid prototype and multidisciplinary teams to allow numerous, and nearly simultaneous, iterations.

Inspired, in part, by approaches and techniques commonly employed in food industry test kitchens, this method requires a devoted team, incorporating all appropriate disciplines and allowing a broad range of process options for comparison and contrast as to efficacy, scaling and suitability.

This method typically postpones confirmation of a concept until several iterative cycles have been conducted, to preserve flexibility and to allow incorporation of new ideas into a synthesized set of solutions. Traditional approaches frequently focus early on a preferred outcome rather than permitting the open consideration of alternatives.

In rapid prototype, numerous potential processes may be evaluated and ranked for strengths and weaknesses. Experimental work and iterative prototype testing determines the right combination of conditions for each potential stage or step in the process. By combining unit processes that are most promising, a new process train can be defined, installed and tested, incorporating the best attributes and practices of the variations considered. And, of course, as with tasting in a “test kitchen,” the product is sampled, analyzed and tested without delay.

Why outsource development?
Companies outsource work for many reasons, often expecting to reduce costs and time to completion or to resolve resource availability issues. Sometimes the reason is safety, secrecy or anticipated production problems.

Many companies presume that cost is the easiest factor to assess and, consequently, they allow the purchasing department to evaluate the decision to “make or buy” developmental services. Unfortunately, many purchasing executives lack the information for an in-depth analysis and understanding of all relevant costs and risks. For example, in comparing the “price” quoted by an independent facility to an internal “budget,” a purchasing executive may ignore critical risk factors or competition for internal resources simply because that information is not presented to him.

Some companies have saved millions of dollars by employing outsourced facilities to take the risks in scale-up, notable among them, firms in the pharmaceutical industry. There are several examples in our database where the world’s foremost experts in a particularly narrow field of chemistry learned to their horror that the impossible does occur.

In one memorable case, a client company assured us that its fluorinated product was entirely stable and couldn’t damage our all-glass, high-vacuum distillation system. The glassware was replaced. Had this work been performed in the client’s facility, the notoriety and delays in incident investigation and equipment replacement might have had disastrous consequences for other products and work scheduled in their facility.

“There are so many constraints for companies — some initially unforeseen — in new product development,” says Mike Keenan, a retired senior chemist from Exxon who has worked and consulted on a number of projects at Pressure Chemical. “Since many companies are committed to existing technologies, it’s difficult for them to have the equipment, capital and, sometimes, the mindset to develop new products and processes efficiently. And companies vary in their strengths. Some are superb at taking someone else’s process and making it more efficient and effective. Others are better at discovering a new process from scratch. In any event, outsourcing certain stages of the product development process can bolster total development efforts,” according to Keenan.

“You need to develop new products outside of the typical constraints of manufacturing, preferably where you can brainstorm for ideas with operators, chemists, mechanics, engineers and regulatory specialists,” Keenan added. “You need to be in a place where change is anticipated and facilitated, not where change requires sign-off at several levels and can take weeks or months.”

Changing equipment and process procedures are germane to the development process. “Unanticipated issues arise during scale-up; it’s common to change equipment and conditions midway through the development process, even during the course of a reaction” said Brandon Ritchie, a senior project manager at Pressure Chemical. “It’s much easier to change something in a well equipped pilot plant than in a client’s production facility. Safety, flexibility and speed are everything in process development,” he added. Pressure Chemical’s project leaders are given full authority to accept client initiated changes in equipment and operating conditions so long as the change conforms to defined safety requirements.

For example, a new client project required some dramatic modifications to the distillation of a high melting monomer. The attempted distillation resulted in a lot of freezing in the process piping. The problem was solved by injecting an appropriate solvent into the overhead to deliver the product as a solution. “We had the ability to modify the equipment quickly and to develop a new, highly successful process for the distillation,” Ritchie said, adding that this preserved the delivery schedule for the product.

Regulatory issues
Large rapid prototype Shenzhen companies are well aware of the impact of federal, state and local regulatory issues in product and process development. Smaller companies, especially ones that do not manufacture novel chemical products, may be totally unaware of the regulations affecting new chemicals. An independent pilot facility that specializes in innovative materials maintains an awareness and working knowledge of the rules, limitations and regulations impacting its customers’ development efforts. For those without the internal regulatory capability, an early consultation with an independent pilot facility should at least identify regulatory issues.

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Rapid prototype Tooling are often made using FDM technology. The part was made from extruded black ABS and was used for some functional testing.

Initial prototype

3M began this phase by creating stereolithography (SLA) patterns with its in-house SLA equipment. Overflow SLA work was sourced to Vista Technologies. The SLA prototypes were used by engineers and industrial designers to check fit and form. The same prototypes were used by 3M packaging engineers to create conceptual mock-ups of product packaging. They also made excellent tools for ergonomic and usability studies.

To mimic the soft under pad of the sanding tool, Vista used PolyJet(TM) rapid prototype technology. PolyJet was chosen because it can use either of two soft-durometer (a hardness measurement) materials that can be run to gain similar quality parts as SLA technology. TangoBlack, a material with a score of 61 on the Shore A durometer scale, was the best fit. Within days Vista was able to supply 3M with their simulated soft-durometer under pads for more testing.

The bottom pad for the hand sander was prototyped using TangoBlack material from the Polyjet technology. This material is a 61 Shore A material that mimics the properties of santoprene.

At the same time, a gripping/tensioning mechanism for the sanding media was being developed. At this point, the sub-assemblies were merged into a refined set of CAD databases. Additional SLA parts were created to evaluate the new mechanisms. With each new prototype, the team was able to investigate new features in the design. Because these rapid prototype parts could be created cost-effectively in a matter of hours instead of days or even weeks, the team had the ability to study complex forms and details in a manner not possible using traditional machining and fabrication techniques. In some cases multiple iterations were generated in one or two days.

On the left is the hand sander from the prototype tool and the hand sander on the right is from the production tool.

Second-Generation Rapid Prototypes: More Realistic Simulations
In the second generation of the prototypes, 3M needed the hinge function and material properties to be simulated more realistically. After a few design changes were made to the CAD data, Vista Technologies supplied 3M with a Fused Deposition Modeling (FDM) prototype.

The FDM part, made from extruded black ABS, allowed for more robust testing and provided similar specified material properties in weight and strength as the final part would have. This prototype was able to handle a variety of tests that allowed 3M to modify their design before production tooling was released.

Rapid Tooling Takes Over

Once 3M completed its work with prototypes, it was time for rapid tooling. Vista Technologies quickly created aluminum tools. Milled at 42,000 rpm with high-speed milling technology and a proprietary fixture system, these tools were made for quick turns and quick modifications.

A core and cavity of a 1+1 family tool of the hand sander top handle. The mold finish is as machined.

The aluminum tools could be modified, polished, textured, welded on, and were capable of shooting 10,000-plus parts. Vista Technologies supplied injection-molded parts within two to three weeks of usable CAD data. By getting specified material parts in hand, 3M could complete their required testing.

A computer rendering of the hand sander concept before prototype.

The rapid tools supplied by Vista Technologies were for multiple parts that made up the sanding products. The parts were made in family tools–meaning several related parts were made in the same tool. By adding runner shut offs to the tools, 3M could turn on or turn off certain parts of the tool–thereby making only the parts they needed. This kept costs down while minimizing wasted material in extra mold inserts. The molds were made with hand pick-outs and manual slides to capture several undercuts in the part design.

3M chose the rapid tooling approach because it allowed them to quickly evaluate different part features and molding parameters. Tooling changes could be completed and parts resampled for evaluation in just a few days. This was a tremendous advantage to 3M.

From an engineering standpoint, they were able to sample several materials for strength and repetitive testing. They were also able to compare the functionality of various latch mechanisms and to check material flow and gate locations (points where material is injected into the tool).

A close-up of a production 3M hand sander. Many methods of rapid prototype and rapid tooling were utilized before production tooling was released.

A 1+1 aluminum mold showing the handles molded in different colors for marketing review.

From a marketing standpoint, along with sampling different materials, they also were able to mold parts in a variety of colors to get important feedback from focus groups. By the time databases were released for production tooling, the mold designs had been optimized and the material and color strategies were in place.

By using rapid tooling, 3M discovered many things in the functional prototypes before cutting production tools. The gating was changed on the production tool, the snap-fit features were redesigned, the handle was modified and ultrasonic energy directors were added for sonic welding of parts in final assembly.

Summary

As rapid prototype and rapid tooling technologies become more sophisticated, the importance of picking the correct technology for product applications can be critical to gaining a competitive edge. As 3M found, a combination of RP and RT technologies and materials helped them save money, speed development time and establish a foothold in the marketplace.

We all know what Mazda is. But as per what a hydrogen vehicle is, that is something not quite familiar for most people. You see, a hydrogen vehicle is actually considered as an alternative fuel vehicle, or an AFV, for instead of using the usual type of fuel or gas to give it power, the hydrogen vehicle can run using hydrogen as the primary source of its power.

So now the question is what is the connected between the Mazda brand and hydrogen vehicles? The answer is quite simple. You see, Mazda has been doing research on hydrogen vehicles. After all, the company has sure been showing very keen interest in this type of vehicle. Perhaps Mazda is still trying to find the answer to some problems that hydrogen powered vehicles pose. One of these is that hydrogen for cars can be quite costly and the vehicle does not perform well. However, with the type of technologies that the industry is capable of doing, perhaps the future is starting to get brighter for Mazda and its interest in hydrogen powered vehicles.

Of course, despite the blatant interest Mazda has with this kind of vehicles, the company still has the time and the capacity to continuously produce new vehicles in their vehicle range. Also, it still continues on creating products for the market like Mazda Tribute auto parts among many others. The company also is still continuously designing, testing, and producing new vehicles for the market.

The hydrogen powered vehicle interest that Mazda has displayed has been noted some fifteen years back. In fact, it has already created various prototype vehicles that they claim to hold the capacity to run on hydrogen. If you would remember the Mazda HR-X Prototype vehicle, this is one concept car that the Mazda has shown off to the motoring public. And it was during the Tokyo Motor Show done back in the year 1991 that the company introduced this hydrogen vehicle prototype. What this one held was a rotary engine that could run on hydrogen.

Years have passed and the interest on hydrogen vehicles has not yet waned for Mazda. And many enthusiasts are on guard and trying to see what developments the company has in store for the future.

rapid prototype is a process wherein a working model or prototype is developed for the purpose of testing the various product features like design, ideas, features, functionality, performance and output. This process of development of working model is quite quick. The user can give an early feedback regarding the prototype. Rapid prototyping is, generally, a significant and essential part of the system designing process and it is believed to decrease the project cost and risk.

The rapid prototype that is developed by the process of rapid prototyping is based on the performance of earlier designs. Hence, it is possible to correct the defects or problems in the design by taking corrective measures. The product can be produced if the prototype meets the requirements of all designing objectives after sufficient refinement. There are many advantages of rapid prototyping.

Rapid Prototyping -Advantages in brief: Rapid prototyping has manifold advantages. It can provide with concept proof that would be required for attracting funds. The prototype gives the user a fair idea about the final look of the product. Rapid prototyping can enhance the early visibility. It is easier to find the design flaws in the early developmental stages. Active participation among the users and producer is encouraged by rapid prototyping. As the development costs are reduced, rapid prototyping proves to be cost effective. The user can get a higher output.

The deficiencies in the earlier prototypes can be detected and rectified in time. The speed of system development is increased. It is possible to get immediate feedback from the user. There is better communication between the user and designer as the requirement sand expectations are expressed in the beginning itself. High quality product is easily delivered by way of rapid prototyping. Rapid prototyping enables development time and costs. There are many innovative ways in which rapid prototyping can be used.

Despite all these benefits, there are many people who believe that there are many disadvantages of rapid prototyping.

Disadvantages of Rapid Prototyping: Some people are of the opinion that rapid prototyping is not effective because, in actual, it fails in replication of the real product or system. It could so happen that some important developmental steps could be omitted to get a quick and cheap working model. This can be one of the greatest disadvantages of rapid prototyping. Another disadvantage of rapid prototyping is one in which many problems are overlooked resulting in endless rectifications and revisions. One more disadvantage of rapid prototyping is that it may not be suitable for large sized applications.

The user may have very high expectations about the prototype’s performance and the designer is unable to deliver these. The system could be left unfinished due to various reasons or the system may be implemented before it is completely ready. The producer may produce an inadequate system that is unable to meet the overall demands of the organization. Too much involvement of the user might hamper the optimization of the program. The producer may be too attached to the program of rapid prototyping, thus it may lead to legal involvement.

The cost reduction benefit of rapid prototyping also seems to be debatable, as sufficient details regarding the calculation basis and assumptions are not substantial.

Go to rapid prototype Zone to get your free ebook on Prototyping at Prototyping. Prototype Zone also has Rapid Prototyping Forum, Prototype Manufacturing Blog and other information on Prototype Information and daily news. You can Find Prototype Zone at.

Using an Arduino, a servo, an optical sensor and a 16×2 LCD screen to create a rapid prototype device which will track a cumulative count (a count occurs each time the opto is interrupted) and a servo to simulate usage. Check out www.nyccnc.com for the code and vendor links.

Rapid Prototype Testing of a longer tag inlay that lays flat in the track. In addition, an alternate reader antenna location was tested. The results of the two tests and the results are shown on this short video that demonstrate the solution design capabilities at ODIN.

Using an Arduino, a servo, an optical sensor and a 16×2 LCD screen to create a rapid prototype device which will track a cumulative count (a count occurs each time the opto is interrupted) and a servo to simulate usage. Check out www.nyccnc.com for the code and vendor links.