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Why Use Rapid Prototype Models
There are obvious benefits in the production of Three Dimension 3D Prototyping or Rapid Prototyping with the quick solid models produced from CAD data. Such 3D models are used to verify and test designs, communicate the new product design with others and make single one-off parts. The main professionals to take advantage of Rapid Prototyping would be Engineers involved primarily in manufacturing. Other more varied professions to use 3d prototyping would be artists, architects, game designers and surgeons.
With the advanced technology available today in Rapid Prototyping the designer can take advantage by decreasing the development time of the design, minimize costly mistakes and increase the effective communication of the newly designed product.
3D Prototype / Rapid Prototyping
3D Prototype or Rapid Prototyping is the technology to fabricate a solid physical object or assembly from three dimensional computer data. The rapid prototyping process involves adding or bonding surfaces together into layers to form solid objects or assemblies of objects.
There are varying forms of Rapid Prototyping processes under the varied names of:
Three dimensional printing, solid freeform fabrication (SFF), layered manufacturing, additive fabrication and computer automated manufacturing.
The "rapid" construction of a model with today's methods can take from several hours to several days, depending on the method used and the size and complexity of the model.
Types of Rapid Prototyping
Additive Fabrication - The rapid prototyping machine reads the data from a CAD model and lays down successive layers of liquid, powder, or sheet material, and builds up the model from a series of cross sections. These layers are joined together or connected automatically to create the finished shape. The main advantage to additive fabrication is its ability to create almost any shape or geometric feature.
Solid Freeform Fabrication - Sometimes the free form fabrication technique uses two materials in the course of constructing parts. The first material is the actual part material and the second is the support material (supporting overhanging features during construction). The support material is later removed by heat or dissolved away with a solvent or water.
Selective Laser Sintering (SLS) - Primarily used for one-off functional prototypes providing a cost effective solution with more durable parts than SLA. SLS is also suitable for producing small batches of functional production parts, provided their natural colour is acceptable and they are not required to have a cosmetic finish. The material produced from SLS rapid prototyping is appropriate for low to mid-volume production or prototypes that need to display functional end-use performance properties.
Stereolithography (SLA) - Stereolithography parts are produced by laser curing of an epoxy resin based photopolymer. The parts created are generally very crisp and rigid, but can be prone to breaking if overstressed.
Rapid Prototyping Process
- 3D design constructed through 3D C.A.D software such as Autodesk Inventor, Pro Engineer or Solidworks.
- Three Dimensional designs converted to a format that can be read by the rapid prototyping method. Suitable file types are generally STL or IGES format which coordinates the shape of the object for translation by the Rapid Prototyping.
- The rapid prototyping machine processes the data supplied and creates sliced layers of the proposed model.
- The physical model process begins with the first layers and as the model is lowered each subsequent layer is added until the model is fully completed.
- The model is removed from the rapid prototyping machine with any supports that were required to produce the model, which is then finished of and cleaned.
3D Printing is an ideal addition to CAD and offers a low-cost alternative to traditional rapid prototyping for building concept and working models. 3D Printers are designed for workstation and network access much like a standard printers. Both rapid prototyping and 3D printers build models layer by layer from STL data. The cost difference per part between 3D printing and rapid prototyping systems can be significant. Including material, machine depreciation, system maintenance and labor, a single part built using rapid prototyping can cost nearly twice as much compared to 3D printing.
3D Printing Information
They can be used in an office environment.
3D printers are generally reasonably small and in some cases can sit on a desktop. Rapid Prototyping machines are much larger, generally free-standing, and often require plenty of electricity. 3D printers are designed to use materials in cassettes or other enclosures, rather than in bulk as rapid prototyping machines do. This makes 3D printers tidier to have in an office and makes it easier to change materials if required.
3D printers produce smaller parts.
3D Printers are smaller than rapid prototyping machines and are limited to making parts that will fit roughly in a cube 8 inches on a side. Rapid prototyping machines provide a chamber at least 10 inches on a side. The smaller 3D Printers also mean that it's not possible to make as many parts at the same time.
3D printers are easier to use.
3D Printers require very little if any at all training compared to rapid prototyping machines. Some 3D Printers make it easy to start producing 3D models from the printer straight out of the box.
3D printers are cheaper to maintain.
You can expect to spend several thousands more keeping a rapid prototyping machine maintained and fed compared to a 3D Printer. The size and number of the models may be an issue with 3D Printers but for small 3D samples and a quick cheaper product they can not be beaten.
3D printers are not as accurate.
Rapid prototyping machines tend to produce more accurate and in some cases produce better finishes than 3D printers. However the difference is very small and the specs are very similar for like-sized parts.
Limited material choices.
3D printers don't provide the same range of materials as rapid prototyping machines. Some materials such as ceramics and metals are not available to 3D printing but only to rapid prototyping. However it's possible to make functional parts for most applications, and the materials available are usually acceptable for concept modeling.
3D Printing
3D Printers have evolved from the rapid prototyping requirements of customers and designers for quick design and rapid 3d prototyping with a low cost and availability to use in an office environment.
