Rapid Prototype Blog

Posts Tagged ‘Technology’

Developments in Formula One but also in normal Cars move almost as fast as the cars themselves. Rapid prototyping is a method which allows new components to be built and tested within a day.

With the advent of 3D printing technology the perimeters of design and engineering protocols have changed. Traditional protocols for engineering and design work required long periods of time between stages of development. 3D printer technology has dramatically shortened the time necessary between stages. Before the development of 3D printing technology prototyping required many man hours to produce a working prototype and the time necessary was multiplied each time a design change to the prototype had to be made. This added to the cost of product design and delayed products from moving to the next stage of development. 3D printing technology saves design teams a considerable amount to time and energy to produce prototypes and the application of design changes.

3D Printer Prototypes

3D Printer Prototype Testing

3D Printer Prototypes

With 3D printing technology come many advantages for the production of prototypes. From the conceptual to testing stage the technology has improve production speed, cost, and simplicity. A 3D printing system using rapid prototype technology enhances the design process by producing a 3 dimensional model. The 3D printing system produces an actual model that can be seen and manipulated by designers during various stages of the development process which helps engineers to facilitate prototype corrections and enhancements. Compared to a 3D printer, usual methods of producing prototypes is time consuming, costly and has to be repeated even if the smallest change is made to the design. Using a 3D printing system to enhance product designs is more efficient and cuts a great deal of time off the various stages of product development.

A 3D printer helps to reduce the bottom line cost of research and development by facilitating the prototyping process. Product development is a costly and prototype design and production can add considerable expense to a project. Multiple design changes, failure to meet deadlines and retooling only add to the bottom line expense of the production process. Utilizing a 3D printer will enhance the design process and cut costs where design changes have to be made by eliminating many of the costs associated with prototype production. With a 3D printing system no additional retooling or reengineering is necessary, because changes only have to be made in the computer assisted design software program. The whole process of creating, changing and constructing prototypes is enhanced through the use of 3D printing technology.

3D Printer Prototype Testing

3D printing technology assists in the prototype testing phase by producing prototypes in a more efficient and time sensitive manner. Where redesigning, retooling and recreating prototypes took a considerable amount of time, the 3D printing system can have a redesigned prototype ready for the next phase of testing in a much shorter period of time then conventional methods. Testing often requires product redesign and retesting, by having a swift technology like a 3D printer, testing can continue according to schedule without any undue delays and expense. It is not very often that a product is able to survive the testing phase of product development without some kind of design change. The 3D printer allows designers and engineers to utilize the advanced technology to their advantage and create better products.

Product testing is an important stage of new product development and a 3D printing system can enhance the testing phase and make the results more effective. Because a 3D printer reduces testing costs the process can be that much more effective. No one wants to be the one who tests a product after they have spent a substantial amount of money on it. As 3D printing technology continues to advance the product testing and development phase everyone will benefit from the technology. When a company can reduce research and development costs by using 3D printing technology, every one will benefit from the savings. The costs or savings for the testing, designing and producing of new products is always passed on to the purchaser of those products.

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.

Polyjet technology has found a valuable and functional position in today’s competitive business environment. Polyjet printing technology has helped design companies who’ve been searching for quicker methods to move products from the design and manufacturing stages onto the consumer market. Polyjet technology moves products more rapidly and cost efficiently from the design stage to a finished product. Polyjet printing techniques are easily able to produce prototypes which are clean, smooth and quickly produced with rapid prototyping technology. Utilizing a number of materials available Polyjet technologies are able to produce a wide range of models, products and prototypes. With the number of design companies requiring rapid prototype production, Polyjet printing has become the desired technology and prototyping tool of choice.

Polyjet Technology

Polyjet Advancements

Polyjet Technology

Polyjet printing continues to utilize innovative and new approaches in 3D prototyping hardware, software and fabrication materials. Polyjet printing and a function of rapid prototyping technology is a design process using computer programming to guide the creation of a three dimensional model through the layering of fabrication material. The Polyjet heads deposit fabrication material in a building tray layer by layer and with concise precision until the prototype is built to complete specifications. Polyjet printers are able to use many different types of fabrication materials to build models and prototypes. Polyjet technology uses resins, polymers or photopolymers either singularly or in different combinations to build many different types of models.

Polyjet printing techniques utilize computer assisted design (CAD) which guides the building process step by step and ensures the correct construction of even the most complex of prototype designs. Polyjet printing heads are able to layer precise amounts of fabrication material during the layering process and build prototypes rapidly and accordingly to design specifications. During various stages of the Polyjet building process ultra-violet lights cure the fabrication materials which harden and produce a functional model or prototype. The Polyjet printing process is simple and easy including setup, printing and cleaning of the prototype model or product. Polyjet techniques for producing prototypes assist engineers in solving complex design issues early on in the development process.

Polyjet Advancements

Polyjet technology advancements are assisting designers to solve even the most complex design issues in the production of prototypes. A wide range of design flexibility is available to engineers with Polyjet printing techniques that were not previously available. Advancements in the computer assisted production of models now permits design changes to be implemented during any stage of the process. With the introduction of new polymer fabrication materials and the ability of Polyjet printers to utilize multiple materials in a single prototype project, designers can engineer many new features into their prototypes and models.

The introduction of advanced Polyjet technology allows the production of prototypes using thinner building lines, innovative fabrication materials and design accuracy. Polyjet printing technology continues to advance the ability to produce high quality and sophisticated prototypes. Polyjet printers are easy to program, set-up and rapidly produce prototypes. Instant and fully cured prototypes which need little post production work make Polyjet printing technology faster and very cost efficient for today’s competitive businesses and companies.

Spin Casting has brought rapid prototype technology to a completely different level of production efficiency. With the capability of producing prototypes in different metals spin casting has given companies options never before experienced in rapid prototype techniques. Now with spin casting technology fragile, functional metal parts can be manufactured with rapid prototype models. Spin casting can cut production times by a considerable percentage and have prototypes available for testing the same day as production. The spin casting technology also eliminates the need for considerable post production tooling and refinishing. Spin casting technology is also easy to use with all the custom features necessary to produce even complex design specifications.

Spin Casting Fabrication Metals

Spin casting technology can accommodate a number of metals to produce fine quality prototypes that are fully functional and produced according to design specifications. Using rubber molds a variety of metals can be used with spin casting technology to produce a variety of finished products. Spin casting can produce prototypes consisting of zinc alloys which are a favorite casting metal, as these metals can accept a variety of surface finishing compounds. These alloys are commonly used in spin casting to replace aluminum, copper and low-grade steel. Spin casting prototypes are suitable for electroplating to produce the appearance of brass, silver or gold.

 

Spin casting can also produce prototypes in many other types of materials as well. Using polyurethane, polyester, epoxy or wax; spin casting can produce a number of products in a variety of materials. Comparing the production cost of spin casting and traditional tooling has spin casting as the most cost effective method of production. Spin casting can produce the same products as traditional tooling and molds but for a fraction of the cost. With spin casting an additional feature is be able to control the number of items manufactured. With traditional manufacturing, single or small item orders are generally more expensive with prices decreasing as unit numbers increase. But spin casting costs remain stable throughout the production process regardless of the number of items produced making it very cost efficient.

Spin Casting Fabrication Steps

Spin casting requires the use of molds that are made from a silicone based material and can accommodate the original parts to form exact details of the models used in production. Once prepared the spin casting molds are hardened and the models are removed leaving detailed molds that will be used for prototype production. With spin casting temperatures reaching around 400C air vents are cut into molds to allow gases to escape during the production process. Spin casting uses centrifugal force to inject fabrication material into molds ensuring all details of the model are reproduced in the prototype. Spin casting allows for complete adjustment of production speeds, pressure controls and cycle times. Prototypes produced by spin casting are precision products that will meet all design specifications and tolerances.

Spin casting cuts the time needed to produce prototypes by a considerable amount and will have prototypes available for the testing phase in a shorter amount of time. Spin casting technology can support post production finishing by being able to use a wide variety of materials. Spin casting techniques are easy to use, cost effective and a time conserving technology for the production of rapid prototypes.

The technology used in rapid prototyping printers for producing 3D models is computer assisted design (CAD) software which directs hardware to precise specifications to produce three dimensional models. The efficiency of rapid prototyping to produce models for various companies and allow design changes to be made quickly and easily has found this technology an excellent solution for fulfilling their rapid prototyping needs. As the implications for rapid prototyping printers continue to develop the applications for the manufacturing of products is expanding. If a product is desired by the business they can simply purchase a CAD file upload it and use rapid prototyping printers to reproduce it. With fabrication materials for use in rapid prototyping printers continuing to advance the use of metals, plastics and polymers contributes to the wide application of rapid prototyping printers.

Convenience of Using Rapid Prototyping Printers

Rapid prototyping printers not only make product availability more convenient for companies but for consumers also. The technology once used only by manufacturers is now available for consumer use in their business or at home. Rapid prototyping printers provide an enhanced ability for the production of models and products. If a new brush or comb is desired, rapid prototyping printers can produce one very conveniently. Rapid prototyping printers can be used for a variety of products constructed of numerous kinds of materials. The technology used in rapid prototyping printers is computer assisted design software utilized to build a 3 dimensional model. The model is produced layer by layer until an exact reproduction is produced according to the specifications dictated by the program.

If a small business needs a product or model produced there is no need to maintain workshops with specialized tools or expensive skilled craftspeople as with traditional modeling. Rapid prototyping printers can provide the technology necessary to produce 3D models more conveniently and in shorter periods of time and for less money. In today’s business environment in order for a small business to grow the capability to produce products in a cost efficient manner is crucial for success. Rapid prototyping printers provide the technology for small businesses that are seeking more convenient and cost effective manufacturing options.

Growing Applications for Rapid Prototyping Printers

The computer assisted design applications of rapid prototyping printers are numerous compared to traditional prototyping methods. Traditional methods required the use of large, bulky and sophisticated equipment which also required a major investment for businesses to own. Rapid prototyping printers however are reasonably sized, compact and much less expensive. The set up time and simple operation has made rapid prototyping printers popular for creating models, machine parts and toys. The almost unlimited flexibility and potential applications of rapid prototyping printers to create replicas is a distinct applications advantage of this technology over traditional methods. If a CAD program can be created and suitable materials developed the application of rapid prototyping printers is immense.

Also, unlike some prototyping techniques the rapid prototyping printers produces no toxic chemicals from nor uses any toxic substances during the production process. Due to their safe operation the potential locations for where rapid prototyping printers can be set up and operated increases their application potential. Additional advantages gained from the application of rapid prototyping printers is that post production work is minimized, only the removal of excess materials produced during the production process is necessary. The applications of rapid prototyping printers are many including reduced costs, efficiency and safety. As new innovations for rapid prototyping printers are developed so will additional applications and markets open up as well.