Rapid Prototyping

Elements of Rapid Prototyping

The growth in computing power has had a major impact on modelling with computer-aided manufacture.
Rapid software and hardware developments allow new opportunities and exciting new technologies to create dynamic modelling of ever-greater complexity.
Models can be simulated by designers using software, tested and tried virtually before sending to a variety of peripheral machines for prototype manufacture in an ever-increasing range of materials.
The ease of sending this digital data across continents for manufacture of prototypes has major implications for data and design protection.

Various new technologies, namely those related to 3D printing, allow for prototypes and products in small numbers to be easily made for little cost.

Manufacturing techniques that add material in order to create it. Rapid prototyping techniques.
Rapid Prototyping (RP) techniques are additive (as opposed to subtractive) by nature (they build up models like a layer cake, CAM-applications slice up CAD-designs for printing).

This makes them:

A 3D printing technique that places melted layers of material on a bed to build up a 3D model:
FDM is the most common type of 3D printing.

It is an additive technique, that uses a heated nozzle to melt a polymer string, and accurately builds up a model layer by layer.
It’s quick, affordable and can be used with various types of (biodegradable) PLA-filament.
Easily operated by a basic laptop/pc.
Lower degree of detail, PLA can tear.
Support structure printing and cleaning can give a messy result that requires additional effort such as sanding to clean up.

Advancements in 3D printing have resulted in the ability to have a 3D
printer at home.
Consumers can download plans for products from the internet and print these products themselves.

A rapid prototyping system that creates a 3D product by converting it into slices, cutting the slices out and joining the slices together.
It is an example of Paper-based rapid prototyping.
However plastics and metals also can be used instead.

Model is also built like a layer cake, with thin sheets of foil material.
Each layer is cut from a gross material sheet, which creates some waste.
The layers are built up and treated with a heated roller to make the layers connect.
The end result is detailed and smooth.
Great for one-off prototypes, small batches.

An additive manufacturing technique that uses a laser to fuse small particles of a powder material into a mass that has a desired 3D shape.

Very similar to SLA and LOM, but now the laser creates a chemical reaction with a special powder, and is also finished with a heated roller.
Very detailed and smooth end result.
No support structure needed.
SLS is generally expensive and more difficult for consumers to obtain, especially compared to FDM.

A modelling technique that creates 3D models layer-by-layer by hardening molecules of a liquid polymer using a laser beam.

Model is built up layer by layer, by lasering resin, causing a chemical reaction in the resin, bonding layers very strongly.
Highly detailed and strong results.
Only the lasered resin reacts, unused resin can be reused, so this technique is low on waste.
Can even produce master molds for manufacturing.
Great for one-off prototypes, small batches.

Slow process; have to build internal structure, supports and raft.
Therefore not suitable for volume production.
Limited to the size of the bed or work area; this may result in numerous parts (sub-assemblies).
For some of the techniques the choice of materials is limited.

A 3D-printing technique that places melted layers of material on a bed to build up a 3D model.

A system that virtually slices a 3D CAD model into thin layers, then cuts out each layer from a roll of material using a laser or plotter cutter.
The layers can then be glued in the correct order to create a 3D model.

An additive manufacturing technique that uses a laser to fuse small particles of material into a mass that has a desired 3D shape.

A modelling technique that creates 3D models layer-by-layer by hardening molecules of a liquid polymer using a laser beam.