Rapid prototyping (RP) refers to the physical modeling of a design using a special class of machine technology. RP systems quickly produce models and prototype parts from 3D computer-aided design (CAD) model data, CT and MRI scan data, and data created from 3D digitizing systems.
What is Rapid prototyping?
Rapid prototyping is the technology in which 3D CAD model is converted into physical model by sectioning it into number of thin slices and the data is passed to the RP system where the laser fuses the powder resulting in complex shapes.
What are the applications of Rapid prototyping?
Although there is a big listing of prototyping applications. This technology is maturing rapidly specially in automotive, medical, toys building, packaging, aerospace, electrical, scientific applications and so on.
Few examples are here:
- Why to take a risk of getting unrealistic quotes from your suppliers by sending 2d drawings, when you can send inexpensive 3D physical part which will not only help to save money at the end but also helps to open new options to manufacture the part or tooling.
- Manufacturers who need parts in small quantities where tooling or production cost is not justified.
- Sometimes it is difficult for the designers or toolmakers to visualize or find out the problems in the drawings, by having the 3d part in their hands, helps them to figure out the problem and redesign it if required before investing on actual tooling.
- Helps the medical field in many different ways specially for reconstructive surgery by making 3d models created from CT scan of the patient’s body parts.
- Quickly making master model for vacuum casting to produce small quantity of Poly Urethane parts.
- If you are a student, scientist, teacher and you need to make a part for your next project or class demonstration, what to do? Rapid prototyping is the quick answer for you.
- Building my new home but like to see how the design will look like in real life.
- To make some Artistic or unique design for example statue, jewelry, special type of toy even some part is broken of your home appliance which is not easily available in the market.
- Any spare parts or auto part hard to find in the market.
- Tooling inserts for plastic injection moulding direct in steel able to produce thousands of parts.
What is SLS?
SLS is known as “selective laser sintering” Which produces parts from 3D CAD Model by adding layer by layer of powder, CO2 Laser Provides a concentrated beam which fuses the resin material, the temperature in the chamber is maintained little below the melting point of the powder, the laser provides the extra temperature for the powder to melt, The powder melts and solidify where gets traced by the laser. Thus resulting in a solid feature.
What is STL Format?
An STL (Standard Triangulation language) file is simply a mesh of triangles wrapped around a CAD model was defined by 3D systems in 1980s. STL, name is derived from rapid prototyping process, Stereo Lithography, also known as abbreviation of Standard Triangulation Language. This very simple format has become an industry standard for the Rapid Prototyping sector. Virtually all-modern CAD systems now include STL or Rapid Prototyping output as a standard feature.
How to export from CAD Package to STL Format?
To export the CAD model open in the format it is in, save it as Stereo lithography Format.
What is 3d Printing?
As in 2D Printing where a layer of ink is added on the paper, similarly in 3D printing the same procedure is repeated, layer-by-layer the material gets added until the height of the CAD data is been obtained.
How much it will coast to make a prototype?
Prototype cost vary with the process and material selection, the cost will also depend on the dimensions of the CAD Model.
How long will it take to produce a prototype?
It could be few hours to one day depending on the size, shape & accuracy needed. The fastest and efficient technology to be considered is 3D Printing.
What is the maximum size limit of which prototype can be made?
Again it depends on the technology you prefer to produce your prototype, the bed size of the machine decides the maximum limit.
What is Vacuum Casting?
If the number of parts exceeds more than 10 than it is economical to go by vacuum casting method. The process starts with creating an accurate finished master pattern which can be created by any RP technique, the model is carefully placed in the mould box and liquid silicon is being poured over the master pattern, after curing the silicon mould is cut into two halves and the master model is being removed leaving an accurate dimensioned cavity behind, now these moulds are used for casting number of parts of polyurethane, epoxy material. a single mould can produce maximum of 35 to 40 pieces.