Rapid prototyping is a design process in which engineers develop geometric models. Just to test various aspects of the product such as functions, features and performance. Therefore, experts believe that this process reduces waste and allows any design defects to be corrected. So why is rapid prototyping technology growing?
A Brief Introduction to the History of Rapid Prototyping
Rapid prototyping technology (RPT) was first used in the United States. In 1987, 3D SYSTEM introduced commercial rapid prototyping equipment for the first time. PRATT & WHITNEY AND EASTMAN KODAK are the hallmarks of the beginning of industrial application of rapid prototyping technology in the 1990s. The scope of rapid prototyping technology is expanding rapidly and is used by companies such as Boeing in the USA, GM, AUDI, BMW in Germany and many other well-known international companies. By 1992, rapid prototyping equipment had already been used in more than 500 projects in 17 countries.
Rapid Prototyping in China
In China, rapid prototyping technology began to develop in the early 1990s, mainly at Xi'an Jiaotong University, Tsinghua University, Huazhong University of Science and Technology, and Beijing Longyuan AFS Co., Ltd., which dealt with photopolymerization and molten layer modeling. , hierarchical unit production and regional laser sintering molding technology, as well as device research. Corresponding rapid prototyping devices are now commercially available.
The main advantage of rapid prototyping technology is that it reduces manufacturing costs and market response time. This is why manufacturers often choose to do this. The popular and rapidly developing rapid prototyping technology, especially in the field of beauty, is widely used in many fields such as automobile, motorcycle, aviation, military and medical.
How to create a prototype
Rapid prototyping technology has reduced the many uncertainties surrounding a product's suitability for the user. Technology has given product developers space to evaluate, obtain data, and make an informed decision based on user feedback from the first prototype.
Below are the advantages of producing a prototype using the rapid manufacturing process:
Early detection of defects and design errors
Early detection of defects associated with the prototype can limit waste and mass production of defective items.
For quick assessment of cost, time and material requirements
Designing models helps the manufacturer determine the actual value of production. It indicates the quantity of materials needed and also the expected processing time and labor required. This provides the manufacturer with data to create a budget and determine final production costs.
To collect accurate information
Insufficient deliveries only led to higher project costs due to a lot of rework. However, developing a working prototype helps solidify the requirements needed for the final model.
Technically understand the weaknesses of production
By developing a working prototype, you will improve your understanding of anticipated and unforeseen technical design issues. You can then overcome the challenges by applying a well-designed system to the final product.
To determine the machines needed
Manufacturers often face a dilemma when it comes to fast processing. For example, you don't know if existing machines can handle production, or if machines need to be modified, or if new machines need to be purchased. The best way to answer this question is to create a prototype that helps you determine what you need in terms of engine.
Testing product health and durability
Making a prototype makes it easier to determine whether the product will fit perfectly. This saves the manufacturer time, money and material waste during rework. It also helps in evaluating the durability of the material used and its resistance to wear.
To search for resources
A prototype can show the viability of your project. By developing one, you will increase investor confidence and increase the chances of receiving money for your idea.
Get feedback from end users
Obtaining feedback from customers, dealers and customers. Helps identify functional or design errors. This information is critical for designers to correct design errors.
5 rapid prototyping methods
Nowadays, with the development of new materials, especially high-performance materials, and the application of rapid prototyping, more and more advanced rapid prototyping technologies are being developed. Below are some typical ones.
1. Stereolithography Device (SLA)
Liquid photosensitive resin selective curing is a kind of rapid prototyping technology first used in machine prototyping, which is equipped with a tank full of liquid photosensitive resin, the material for SLA rapid prototyping. The liquid resin initially hardens quickly under UV irradiation. At liquid level, you can raise the bench to the next section thickness. The resin is concentrated after computer-controlled scanning with a UV laser beam. By requesting to scan the transverse contour along the surface of the liquid, the scanned area is hardened and given the expected contour. The bench then drops to the height of one layer and is covered with another layer of liquid resin. During the second sweep hardening, the new solidified layer is firmly bonded to the previous layer. This process is repeated until the entire product is formed.
2. Laminated Object Manufacturing (LOM)
This method is based on a 3D model of the contour line of each section and is computer controlled, with the CO2 laser beam scanning the lightweight materials (such as floor adhesive paper) to cut the contours of the layers. Step by step, the layers are connected together and finally form a three-dimensional product.
3. Selected Laser Sintering (SLS)
SLS uses CO2 lasers and powdered materials (such as plastic powder, ceramic powder and powdered metal powder mixed with binder) for molding. First, a layer of powder material is spread on the bench, and then the powder part is sintered under the influence of a computer-controlled laser beam with the cross-section contour information, and the bench is lowered to the layer height. A new layer of liquid resin then covers the surface of the previously solidified layer. By repeating all these steps, a three-dimensional product is finally created.
4. Fused Deposition Modeling (FDM)
Under computer control, the nozzle of the rapid forming machine is heated according to the cross-section contour information while the xy plane moves in the direction of the z axis. The silk material (such as plastic thread) for the silk machine is sent to the nozzle and heated to melt in the tank. It is then selectively coated on the bench and cooled quickly after the cross-section contour is formed. After the one-layer molding process is completed, the bench is lowered to the height of one layer and the next layer is coated. In this way, the circles are finally used to form a three-dimensional product.
5. Three-dimensional printing (TDP)
TDP works with a fast forming machine and is controlled by computer according to the cross-section contour information. The adhesive is selectively sprayed onto the prepared layers of powder material and forms the cross-sectional contour. After completing one layer of molding, the countertop goes down to the level of a cross layer, and then the next layer of adhesive follows. By repeating these processes, a 3D product is finally created.
Rapid prototyping process
Rapid prototyping is a manufacturing technology in which the production process occurs quickly. One method is 3D printing, which seems like a new technology. However, it has been around for over 30 years.
Technology has advanced to the point of automating software and processes. It uses CAD, a process that has had a positive impact on the 3D printing market. Customers can receive frames within 15 days or depending on the complexity of the project.
The introduction of the three-dimensional material addition process was a breakthrough in rapid prototyping. However, the impact of 3D printing was only felt when computer-aided technologies such as CAD, CAM and CAE came into use.
Unlike injection molding and CNC machining, rapid prototyping methods are limited. It is also important to note that 3D printing, stereolithography, and laser sintering all have limitations due to layered materials.
Rapid Prototyping China produces products from heavy tools in a very short time. It offers customers quality models at a lower price. It acquires dimensions, shape and other characteristics through recognition and touch.
The development of rapid prototyping
Traditional manufacturing methods were expensive to set up. For example, processes such as injection molding or CNC prototyping resulted in low volumes and were expensive methods of producing custom prototypes.
The rapid prototyping technique transformed ideas into a realistic concept. Technology advancements in creating high-precision models that function as the finished product have been achieved through a series of validation phases aimed at mass production.
Creating a prototype is now faster than ever. Using CAD data can speed execution based on frequent test results and real feedback. This makes it easier for designers and engineers to bring their ideas to life.
Rapid prototyping technology is the world's most advanced manufacturing technology and new product development method in the 1990s. In developed countries, the adoption of rapid prototyping technology is an important strategy for companies to ensure the development cycle and improve design quality in the development of new products. At present, market competition is becoming more intense and product switching is accelerating.
In order to maintain the competitiveness of our products in domestic and foreign markets, we urgently need to adopt modern innovation methods, while increasing investment in new product development and strengthening our innovation awareness. Rapid prototyping technology enables the rapid production of new product samples of any complex shape without the need for tools, dies and tool holders.
Using rapid prototyping technology, quickly created models or samples can be directly used for new product appearance design, functional verification, etc. It is very beneficial to optimize product design, significantly increasing the success rate of new product development, improving the competitiveness of products in the market, shortening the development cycle, and reducing development costs through the enterprise-wide application of technology. rapid prototyping to realize product innovation. activities reduce.
Rapid prototyping technology is used in many areas. Its scope is mainly in design verification, market forecasting, engineering testing (stress analysis, air ducts, etc.), assembly testing, mold making, medicine, aesthetics, etc. Rapid prototyping technology is mainly used in the manufacturing industry (up to 67%), which suggests that rapid prototyping technology has a huge impact on improving product design and manufacturing levels.
Why do you need rapid prototyping
Rapid prototyping has gained recognition among technical designers. It is a precise means for the manufacturer to realize their final product. Furthermore, metal rapid prototyping has evolved significantly and has become a solution for several industries. Guarantees the realization of any design concept from a variety of metals.
Here's why you need rapid prototyping:
Efficient realization of the concept
Previously, if there were any significant changes to the design, the designer would have to start from scratch or completely restart. However, with rapid prototyping, problems are solved in the process, saving time and resources.
Communicate ideas
To fully convince everyone involved and ensure they are satisfied. You need a physical model to convey your ideas more clearly than using an on-screen visual design presentation. It also provides a channel for actionable feedback that helps refine or improve the design.
Saves costs and time
One of the main reasons why you need rapid prototyping is the ability to develop exact products as per requirements. No special tools are required to alter or alter the design. All you need is a CAD model and the entire process remains the same.
Reduces design errors
With additive manufacturing, design errors can be easily identified before mass production begins.
The future development direction for rapid prototyping
Rapid forming technology still has many shortcomings. Future research and development work will focus mainly on the following aspects:
- Improve the reliability and productivity of the rapid forming system and the ability to produce large parts, especially the accuracy of the rapid forming system.
- Develop a cost-effective rapid prototyping system.
- Improvement and innovation of rapid prototyping methods and processes;
- Quickly develop moldable materials with good performance;
- Develop powerful rapid prototyping software.
Prototypes give you the opportunity to create a design that matches the look and feel of your customers. The process allows you to test the product and production method and experience the end user experience. User feedback allows you to collect enough information, recreate and launch a marketable product.
