Rapid Prototype Blog

Posts Tagged ‘Tooling’

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.

Rapid Prototyping by Objet – post process applications 3D printed model on an Objet polyjet 3d printers.

Go to www.5axissolutions.com for all your CNC machining needs! This video shows an undercut being machined into this Aluminum Foam Tool.

Who are companies there for cheap and instant quotes for custom designed small sized mechanical and plastic parts in 1-10 quantities without going long way around making molds etc? / Alternative way to do tooling?

Ok, I got a great answer yesterday as EmachineShops, but looking for few more to compare. Cheap, fast and don’t ask for bulk quantities.

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.

apid tooling promises to be a powerful solution in the quest to develop better products faster. In the future, rapid tooling will commonly be used to slash the time for the delivery of components in production intent materials.

Presently, there are barriers to the broad acceptance and application of rapid tooling. However, if the definition of rapid tooling is expanded, it can be a powerful and beneficial tool.

Rapid Tooling Defined

The original, and most accurate, definition of rapid tooling is: A 3D CAD-driven process that generates tooling inserts in a layer-by-layer (additive) process for the production of components in end-use materials. In simpler terms, this means building tools from a rapid prototyping process. In the past few years, the definition of rapid tooling has become broader and somewhat unclear:

Any process, technique or technology that significantly reduces the delivery of a tool for the production of components in end-use materials. Translated, this means cutting an aluminum or steel tool can be considered rapid tooling.

When the search for a rapid tooling solution begins, it is common to use traditional tooling techniques as the benchmark. The goal becomes the replication of all the quality of a cut tool while slashing the delivery time and expense. With these standards, the options become limited. These imposed limitations can make it best to seek out a tool shop that is extremely fast and efficient at building cut tools in aluminum or steel. In the evaluation of projects, Accelerated Technologies often finds that a machined tool is a far superior solution. Under the original, narrow definition, rapid tooling has limitations in many areas. These include:

* Tool life

* Accuracy

* Surface finish

* Resin selection

* Tool configuration

* Cycle time

* Part size

Each available rapid tooling solution presents limitations in at least two of these areas. When the strengths and weaknesses of the processes are presented, many elect to use traditional methods that may require more time. It certainly will be a dream come true if technology brings down cost of buildings.

Shopping for a designer house will be one of the choices open to everyone, not the privilege of a few. A 10 to 15 year recycling time for a house will be appropriate, because the recycling cost will be lower than the renovation cost.

Fast prototyping cannot replace our current building practice, but at least it will help to construct a mock-up to improve the design. It is a known fact that a full-size building mock-up is necessary to eliminate errors and the need for future design modifications. Fast prototyping can accelerate the mock-up process, bring down the cost, and speed up the final construction time.

Full-size building component prototypes are not yet in production, because they require detailed connections and some modifications. It is not hard to imagine, that in the near future an entire house will be manufactured by an LOM machine or other RP processes directly. Such a notion is exciting and will revolutionize the building industry. Rapid tooling is a powerful process that can definitely make the building process faster, cheaper, and better.