Originally published on fastradius.com on April 21,
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“Rapid prototyping” (RP) refers to the quick fabrication of physical products using Computer Aided Design (CAD) during the design phase of the product life cycle. It can be used throughout the design process, from concept creation to final testing. Effective rapid prototyping helps engineers avoid potential pitfalls early on, improves a product’s overall quality, and accelerates speed-to-market. Rapid prototyping can also quickly reproduce complex geometry directly from a CAD file without any need for tooling.
There are two types of prototypes: low fidelity and high fidelity. Low fidelity prototypes are rough mock-ups used in the early stages of the design cycle to help designers and engineers understand the form and function of a concept, allowing them to quickly improve on designs. High fidelity prototypes are nearly exact representations of a final design, used to validate the performance, appearance, and ergonomics of the product.
Rapid prototyping is one of the major benefits of additive, but it’s hard to know which type of 3D printing to use. To ease the pressure of selecting a rapid prototyping process for a given product, we’ve broken down six of the most common methods.
During Fused Deposition Modeling (FDM), a heated printing nozzle melts thermoplastic material such as polycarbonate or ABS inside its barrel and then extrudes the liquified material, layer by layer, along a set toolpath. FDM has been around for many years and is one of the most common prototyping technologies because it’s easy, safe to use, and can produce relatively strong parts at a moderate to low price point.
Unfortunately, FDM isn’t known for its structural integrity. The process often produces parts that are porous, have non-uniform strength, and have limited functional testing ability. FDM is also slower than stereolithography or selective laser sintering. Still, engineers should consider FDM a viable option during the product development stage, as it provides a cost-effective means for rapid prototyping.
Stereolithography (SLA) is the tried-and-true rapid prototyping choice for many design and engineering teams. During this process, a computer-controlled UV light laser traces each 2D slice of a part on the build platform, curing a liquid photopolymer resin. Each completed layer adheres to the next and the process is repeated until a full part is formed. It’s fast, affordable, and widely available. SLA prototypes are commonly used for medical devices and models.
Since SLA doesn’t require engineering-grade resins, prototypes made by this process tend to be weaker and unfit for strenuous testing. What’s more, UV can degrade over time and when exposed to humidity. However, SLA parts have a much better surface finish than FDM due to the higher resolution of the laser and the reduced appearance of layer lines. Engineers should consider prototyping with SLA for limited-use parts with intricate designs or higher surface requirements.
Carbon’s Digital Light Synthesis (DLS) uses a photochemical process to build parts. Light is projected through an oxygen-permeable window and down into a vat of UV-curable resin. Then, a digital device projects a sequence of UV images into the resin, the part solidifies layer by layer, and the full part is formed. The printed part is baked in a forced convection oven and the application of heat gives DLS printed parts their exceptional mechanical properties.
This process is ideal for developing high-fidelity prototypes and small, isotropic parts because the printing process is continuous. DLS printed parts are similar in strength and mechanical properties to parts produced using injection molding. DLS is also compatible with a wide variety of industrial-grade materials, making it ideal for multiple part iterations.
However, DLS is not the best prototyping process for printing parts larger than the palm of one’s hand and engineers might have to rethink their designs to account for this process’s supports. Also, it’s typically more expensive than other prototyping processes available and doesn’t have a large build volume.
Selective Laser Sintering (SLS) uses a powerful computer-controlled laser to sinter multiple layers of powdered material, typically nylon-based, into a solid. In addition to nylon, SLS is compatible with elastomeric TPU powders that are mechanically similar to thermoplastics. This rapid prototyping process is particularly well-suited for creating automobile hardware parts.
Prototypes built with SLS are tougher, more durable, and more suitable for functional testing than those built with SLA. This process is also more versatile than SLA, since it can be done using a wide variety of materials while still maintaining uniform strength. However, SLS-printed products are porous, less detailed, more expensive, and take longer to produce.
Multi Jet Fusion (HP MJF) is a powder bed technology that builds up 2D cross-sections using inkjet heads to deposit a fusing agent on a layer of powder that is then fused by an infrared lamp. The parts are then excavated from the build box and blasted to remove the excess powder.
HP MJF is fast, about three days faster on average than SLS. This process can produce functional, chemically resistant, and highly dense prototypes in as little as a day. This makes it ideal for watertight applications, enclosures, and other prototypes that have complex assemblies. Prototypes can also be made in full color, allowing designers to test the aesthetics of a product as well. However, HP MJF can only be used with PA12 nylon and it does not promise high accuracy when it comes to creating small features.
During the PolyJet printing process, a print head sprays a layer of photopolymer resin onto a gel matrix, and proceeds to cure the resin under ultraviolet light. This produces ultra-thin and incredibly smooth layers of material that can give your prototype a superior surface finish. Additionally, the print head can eject droplets of different materials, allowing you to create multi-material prototypes in a single print.
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However, PolyJet shares many of SLA’s vulnerabilities. Prototypes built with this process aren’t very strong and can degrade due to UV sensitivity. Still, if engineers are looking for a rapid prototyping process that’s compatible with many materials and produces an elegant, high-resolution print, PolyJet can be a suitable option.
Choosing the best rapid prototyping process can feel overwhelming. By balancing budgetary constraints, timeline, physical requirements, and other critical factors, engineers can begin zeroing in on the rapid prototyping process that’s best for their project. Partnering with an expert manufacturing partner can help ensure you’re making the right choice.
In rapid prototyping, where innovation takes shape at lightning speed, materials are the alchemists’ elements, the sorcerers’ spells. They can transform a mere concept into a tangible reality, breathing life into your designs and dictating their destiny.
But with many materials vying for your attention, how do you choose the perfect concoction for your specific needs?
Fear not, fellow creators! At NICE Rapid, we’ve mastered the art of material selection, guiding countless businesses through the labyrinth of options to find the perfect match for their prototyping endeavors. Consider this your ultimate guide, a treasure map leading you to the materials that will unlock your design’s true potential.
Like a painter’s palette bursting with vibrant hues, the world of rapid prototyping materials offers diverse options, each with unique characteristics and applications. Let’s explore the key categories:
Plastics reign supreme in rapid prototyping, from the ubiquitous ABS and PLA to the robust nylon and polycarbonate. Their versatility, cost-effectiveness, and ease of processing make them ideal for various applications.
When durability and strength are paramount, metals step into the spotlight. Aluminum, stainless steel, and titanium offer unparalleled performance for demanding applications.
Resins are the artisans of choice for prototypes that demand intricate details and flawless finishes. Epoxy, polyurethane, and silicone each bring unique properties to the table.
Combining the best of different worlds, composites offer a unique blend of properties. Composites achieve exceptional strength-to-weight ratios and tailored performance characteristics by fusing materials like carbon fiber and fiberglass with resins.
Choosing the right material is like assembling a puzzle, where each piece is crucial in completing the picture. Consider these key factors:
Lost in the sea of material choices? Fret not! At NICE Rapid, we’re your seasoned navigators, guiding you toward the perfect materials for your prototyping voyage. Our extensive inventory boasts a treasure trove of options:
But our expertise goes beyond simply offering a vast selection. Our experienced engineers delve deep into your project requirements, understanding your goals, functionalities, and aesthetic desires. We then leverage our knowledge to recommend the optimal materials, ensuring your prototype looks the part and performs flawlessly.
Need a helping hand in navigating the material maze? Our expert consultations provide personalized guidance, helping you make informed decisions and avoid costly missteps.
Choosing the right materials is the cornerstone of successful rapid prototyping. It’s the bridge that connects your innovative ideas to tangible realities. By understanding the nuances of different materials and leveraging expert guidance, you can ensure your prototypes are not just physical manifestations but true embodiments of your vision.
Ready to embark on your material selection journey? Contact NICE Rapid today. Let our expertise guide you toward the perfect materials to transform your concepts into remarkable realities.
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