Rapid Prototyping Explained

Rapid prototyping is a automatic process that has only been available since the 1980s. The techniques used for this method produced models as well as prototype parts. However, more recently they have been used for by sculptors and manufacturing companies to produce intricate shapes and small numbers of superior parts.

Rapid Prototyping using CAD

• When the technology is used for creating parts that are almost exactly the same as the original, the process is called WYSTWYG.
• As part of the rapid prototyping process this entails used a computer aided design (CAD) program and changing a virtual drawing to cross sections.
• Each cross section is thin and lies horizontally in layers to create the model desired.

Using the plan already drawn, which is a virtual design, the CAD program sends data to the machine that in turn adds the layers. They may be sheet, powder or liquid material. The layers match the virtual drawing from the CAD model.

So What is Rapid Prototyping?

Automatically constructing these models while using additive manufacturing or fabrication is called rapid prototyping. Construction consists of joining the layers which forms the final product. The allows the user to construct nearly any geometric aspect desired.

The border that connects the CAD software and the machine being used is the STL file format. This format can replicate the shape by using triangle shaped facets. The smaller the facets the higher quality of the surface. Actually the ‘rapid' in rapid prototyping is not indicative of the time it takes to construct the model. This process can actually take anywhere from hours to days. This depends upon the size of the model, the method and the intricacy of the design.

What to consider with Rapid Prototyping

There is also another factor to consider. The additive system is generally able to produce a model within a few hours, but it depends on how many models are being generated at the same time, their size and what kind of machine is being used. One of the techniques used is called solid freeform fabrication. This type of rapid prototyping uses two different materials. One is for the construction of the model and the other is the support, which is later taken away.

Another method that is used for creating products in higher numbers and is used due to the expense being much less is injection molding. When smaller amounts of products are needed, additive fabrication is not as costly and is much quicker. It is possible for the designers to use a desktop printer to produce these models as long as a 3D printer is used.

The process of rapid prototyping is quickly being supplemented by the process of rapid manufacturing and is considered to be a result of advances in technology taking the next step. Because there are many of these new advances becoming competitors in the public eye, we need to know the biggest difference is the way the layers are constructed to form the parts needed.

The process of building the layers can either be melting a certain material to make the layers or cutting them to allow the connection. When joining materials for lamination the layers are cut quite thin, shaped and then joined to produce the end result. Rapid prototyping is often used for medical, automotive, defense and aerospace industries.

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