Rapid Prototyping Services
Rapid prototyping is an agile strategy used throughout the product development process. Utilizing 3-dimensional prototypes of a product or feature for the purpose of testing and optimizing characteristics like shape, size, and overall usability.
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Rapid Prototyping by Technology
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Rapid Prototyping by Model Type
The variety of available technologies and material allows rapid prototyping to support designers and engineers throughout the product development process, from initial concept models through engineering, validation testing, and production.
Proof-of-Concept Prototypes and Concept Models
Concept models or proof-of-concept prototypes provide designers an opportunity early in the process to validate their design decisions and test a product's viability. Physical concept models can authenticate an idea to colleagues opening up discussions and driving innovation. Concept prototypes are frequently used at the earliest stages of the product development process. Consequently these prototypes are less concerned about appearance but focus on the functionality needed to validate the design before moving the product into higher stages of development.
Appearance Model or Looks-Like Prototypes
Appearance models represent the final product aesthetics but may lack many of its functional aspects. The purpose is to provide a representation of what the end product will look like and how the end user will interact with it. User interface & experience along with ergonomics can be validated early in the development process.
Functional Models or Works-Like Prototypes
Parallel to the aesthetic design process, engineers develop another set of prototypes to test, iterate, and refine the mechanical, electrical, and thermal systems that compose the final product. These Functional models might look different from the final product, but they include core functionality which needs to be developed and tested.
Alpha or Pre-Production Prototypes
An Alpha prototype combines design and engineering to create a minimum viable version of the final commercial product which is designed-for-manufacturing (DFM). This prototype can be used for testing to demonstrate viability for purpose as well as work as provide marketing feedback. It allows engineers to create detailed prototypes that accurately represent the finished product. Making it easier to verify the design, fit, function, and manufacturability before committing to expensive tooling and moving into the production phase.
Architectural Models
Models facilitate communication, providing a shared visual language that transcends technical jargon. They allow architects to explain their designs clearly and concisely, while clients can express their needs and preferences more effectively. Furthermore, models are invaluable tools for identifying potential design flaws or conflicts before construction begins, saving time and money.
3D Printing vs. Rapid Prototyping
3D printing include technologies which utilize a 3D CAD file to create an object by using a computer control to deposit, join, or solidify material. The material is often added layer by layer to create a 3D object. Example technologies include stereolithography (SLA), Fused Filament Fabrication (FFF) also know as Fused Deposition Modeling (FDM) as well as Selective Laser Sintering (SLS).
Rapid Prototyping includes all technologies that allow for the rapid creation of a physical prototype. Example technologies include RTV urethane casting, CNC machining, as well as all the 3D printing technologies.
3D printing is one of many Rapid Prototyping technologies.
Advantages of Rapid Prototyping
Explore Concepts Easily
A prototype elevates initial designs to hold in your hand concept validation. Allows designers to go beyond virtual visualization, making it easier to understand the look and feel of the design.
Save Cost & Time
A physical prototype allows your team to validate design, fit, form, and function before spending time and money on production tooling.
Communicate Ideas Effectively
Physical models empower designers to share their concepts and convey ideas in ways not possible by images on a computer screen or on paper.
Design Iteratively
Design is a process which involves multiple iterations until a product is at it's best. Rapid prototyping provides flexibility to create prototypes quickly and implement changes rapidly and effectively.
History of Rapid Prototyping
Since rapid prototyping is a modern term that encompasses many technologies, we should start with the first "programmable" machine.
The first progammable machine is the CNC machine. The first NC (numerically controlled) machine is built in the 1940s and 1950s, based on existing tools that are modified with motors that moved the controls to follow points fed into the system on punched tape. These early servomechanisms are rapidly augmented with analog and digital computers, creating the modern CNC machines we use today.
In 1983, Charles Hull invented the first stereolithography-apparatus (SLA) for which he was granted a patent in 1986. Carl Deckard appllies for a patent for Selective-Laser-Sintering (SLS) in 1987 and a patent was issued in 1989.
3D systems sells the first commercially available machine in 1988.
For additional 3D printing history click on the info link below to go to the ASME website.
Rapid Prototyping FAQS
What is SLA?
SLA is a 3D printing technology which uses a laser to cure a photo-polymer into a hardened plastic. SLA is one of the most popular processes for prototyping due to its high resolution, precision, and great surface finish.
What is FDM?
FDM is a 3D printing technology also known as FFF (fused filament fabrication). It builds parts by melting and extruding thermoplastic filament through a nozzle depositing layer by layer to create a plastic part.
What is CNC?
CNC machining is a subtractive process. It utilizes 3D CAD files of a part to generate a prototype from virtually any material. It begins with a standard stock material which is systematically cut into a finished part. It is used for both prototypes and production parts.
What is Urethane Casting or RTV?
Urethane Casting is similar to injection molding but without the expense of hard tooling. It is the perfect solution for low-volume custom parts. Urethane casting, also know as vacuum casting, is a manufacturing process which utilizes soft tooling. A polyurethane resin is injected into the soft tool and put under vacuum to cure.
What is Silicone Casting?
Silicone casting is similar to urethane casting but instead of soft tool a CNC machined or 3D printed tool is used. Silicone prototypes are cast using RTV silicones. This process works well for gaskets, flexible membranes, insulators and functional prototypes.
What is Elastomeric Over Molding?
Elastomeric over-molding is a process which bonds a softer material onto a harder base component. It can provide a range of product benefits such as textures that make hand held items easier to hold and use, vibration and noise reduction, greater electrical resistance and increased shock absorbency.