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How Can Your Business Benefit From Fast Paced Prototyping

Simply put, a rapid prototyping process is a procedure or method wherein a design is tested during the early parts of its development.

This type has been proven to be more useful in projects that involve large-scale designs. From the name, rapid prototyping involves quickly constructing a scale down model of large objects through the aid of computerized three dimensional images.

These virtual designs are broken into parts or cross sections which identically represents the actual object. When building the prototype, a machine will read the information from the computer and would construct the images segment by segment until the whole prototype has been created.

Depending on the type of the machines and the models size, constructing a prototype using the rapid prototyping process may take from 3 to more than 70 hours. Others even take months to complete.Usually CAD is used to construct the virtual model which later on is converted to the STL file format. A rapid prototype machine then processes the .STL file and creates layers of the model.

Layer upon layer, the segments are piled on top of each other until the model is created. These layers are glued together by using lasers. These layers are made of either liquid or powdered materials. Afterwards, when all the layers have been laid down, the superstructure of the model is removed revealing the unpolished surfaces of the prototype. The prototype model is then cleaned.

A lot of companies prefer using rapid prototyping because it offers the best benefits to them. Using rapid prototyping processes increase effective communication, decrease development time, reduce the prevalence of costly mistakes, lessen any sustaining engineering changes, and help extends product life through the addition of essential features and remove unneeded features during the early developments of the design.

By allowing engineers, manufacturers and even the marketing and purchasing people take a look at the product during the onset of its development they can identify and correct mistakes while it is still cheaper to do so.

Among the types of rapid prototyping processes include stereolithography, selective laser sinthering, laminated object manufacturing, solid ground curing and rapid tooling. The standard interface between CAD software and rapid prototyping machines is the STL file format.

MacroMind Director (MMD) is another type of prototyping tool which combines a text, graphics, animation as well as music and other sound, and video. This type of tool has been used more commonly in film, engineering, education and business industries. Most of the output is simulations, visualizations and presentations.

Rapid prototyping, otherwise known as desktop manufacturing, additive fabrication, solid freeform fabrication, three dimensional printing or layered manufacturing, has always been in the forefront of development and design. By quickly creating prototypes that are similar to form and function as the actual production unit, developers are able to create a product that meets the expectations of consumers and project sponsors.

Through a combination of rapid prototyping methods and traditional model making, high quality prototypes can be created with less the expense and quicker turnaround times.

Compared to traditional fabrication methods like milling and turning, rapid prototyping is way better in terms of accuracy, speed and quality. By using rapid prototyping techniques complex and intricate shapes can be formed without any complicated machine setup, prototypes can be created from different types of materials or composites, and the process simplifies the whole process of creating a prototype.

Because of the advantage it brings, rapid prototyping services are being offered by companies to engineers and system developers to better understand their product and communicate better with their target clientele. Not only does the technique used by designers, developers and manufacturers, but professions like surgeons, architects, artists and even mere individuals regularly utilize the technology.

Among the services being offered are stereolithography, selective laser sintering or SLS, fused deposition modeling of FDM, laminated object manufacturing or LOM, inkjet-based systems and three dimensional printing or 3DP.

SLS is one of the most used tools in rapid prototyping techniques. In SLS rapid prototyping, a CO2 laser is used to melt powdered thermoplastic materials to create layers. A scanner guides the laser and melts specific areas and materials based on the information fed by the 3D CAD.

Prototypes created from SLS processes are strong and more tolerant to stress. Materials used in the market include DuraForm, CastForm, Somos 201, FR85A and LaserForm. Most of the prototypes created from these materials are usually ready to be used and only require minimal clean up and finishing.

Stereolithography or SLA creates prototype part layers through the use of a solid-state laser. The 3D CAD data guides the laser as it cuts through the surface of a container which normally contains liquid photopolymer material.

In LOM, on the other hand, uses a paper sheet with one side laminated with adhesive. The laser cuts the outline on the paper sheet. This process does not involve any chemical reaction which makes it cheaper and large parts can be made.

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