Advantages and Disadvantages:
Stereolithography provides a quick and simple means to convert CAD models into real objects. This is very useful where time is money. The constraint as mentioned above is that the time to produce three dimensional parts depends upon the size and complexity of the object. The accuracy is very good having tolerance within .004″/inch. The problem again is that SLA devices or machines are too expensive. Photo-curable resin used in Stereolithography can cost as high as $800 per gallon. Then the process involved in SLA produces fumes due to which it requires a well ventilated environment

Best Part of Rapid Prototyping:
Since 1986, the year of its invention, SLA has taken large steps equally in its machine design and resources used for it. SLA is real rapid modeling and is fast switching from rapid prototyping to rapid manufacturing. It can be an exceptionally convenient and valuable process in many conditions and for many industries. It has been used effectively to aid surgeons with ear implants and can be used in almost every industry from jewellery manufacturing to military, power, marine etc. This makes it the best part of rapid prototyping.

At EMS-USA we deliver 3d scanning, reverse engineering, and rapid prototyping service involving both on-site and off-site engagement models. Contact us for Stereolithography Services and other product and services we offer.

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Initial Prototyping

3M began this phase by creating stereolithography (SLA) patterns with its in-house SLA equipment. Overflow SLA work was sourced to Vista Technologies. The SLA prototypes were used by engineers and industrial designers to check fit and form. The same prototypes were used by 3M packaging engineers to create conceptual mock-ups of product packaging. They also made excellent tools for ergonomic and usability studies.

To mimic the soft under pad of the sanding tool, Vista used PolyJet(TM) rapid prototyping technology. PolyJet was chosen because it can use either of two soft-durometer (a hardness measurement) materials that can be run to gain similar quality parts as SLA technology. TangoBlack, a material with a score of 61 on the Shore A durometer scale, was the best fit. Within days Vista was able to supply 3M with their simulated soft-durometer under pads for more testing.

The bottom pad for the hand sander was prototyped using TangoBlack material from the Polyjet technology. This material is a 61 Shore A material that mimics the properties of santoprene.

At the same time, a gripping/tensioning mechanism for the sanding media was being developed. At this point, the sub-assemblies were merged into a refined set of CAD databases. Additional SLA parts were created to evaluate the new mechanisms. With each new prototype, the team was able to investigate new features in the design. Because these rapid prototype parts could be created cost-effectively in a matter of hours instead of days or even weeks, the team had the ability to study complex forms and details in a manner not possible using traditional machining and fabrication techniques. In some cases multiple iterations were generated in one or two days.

On the left is the hand sander from the prototype tool and the hand sander on the right is from the production tool.

Second-Generation Rapid Prototypes: More Realistic Simulations
In the second generation of the prototypes, 3M needed the hinge function and material properties to be simulated more realistically. After a few design changes were made to the CAD data, Vista Technologies supplied 3M with a Fused Deposition Modeling (FDM) prototype.

The FDM part, made from extruded black ABS, allowed for more robust testing and provided similar specified material properties in weight and strength as the final part would have. This prototype was able to handle a variety of tests that allowed 3M to modify their design before production tooling was released.

Rapid Tooling Takes Over

Once 3M completed its work with prototypes, it was time for rapid tooling. Vista Technologies quickly created aluminum tools. Milled at 42,000 rpm with high-speed milling technology and a proprietary fixture system, these tools were made for quick turns and quick modifications.

A core and cavity of a 1+1 family tool of the hand sander top handle. The mold finish is as machined.

The aluminum tools could be modified, polished, textured, welded on, and were capable of shooting 10,000-plus parts. Vista Technologies supplied injection-molded parts within two to three weeks of usable CAD data. By getting specified material parts in hand, 3M could complete their required testing.

A computer rendering of the hand sander concept before prototyping.

The rapid tools supplied by Vista Technologies were for multiple parts that made up the sanding products. The parts were made in family tools–meaning several related parts were made in the same tool. By adding runner shut offs to the tools, 3M could turn on or turn off certain parts of the tool–thereby making only the parts they needed. This kept costs down while minimizing wasted material in extra mold inserts. The molds were made with hand pick-outs and manual slides to capture several undercuts in the part design.

3M chose the rapid tooling approach because it allowed them to quickly evaluate different part features and molding parameters. Tooling changes could be completed and parts resampled for evaluation in just a few days. This was a tremendous advantage to 3M.

From an engineering standpoint, they were able to sample several materials for strength and repetitive testing. They were also able to compare the functionality of various latch mechanisms and to check material flow and gate locations (points where material is injected into the tool).

A close-up of a production 3M hand sander. Many methods of rapid prototyping and rapid tooling were utilized before production tooling was released.

A 1+1 aluminum mold showing the handles molded in different colors for marketing review.

From a marketing standpoint, along with sampling different materials, they also were able to mold parts in a variety of colors to get important feedback from focus groups. By the time databases were released for production tooling, the mold designs had been optimized and the material and color strategies were in place.

By using rapid tooling, 3M discovered many things in the functional prototypes before cutting production tools. The gating was changed on the production tool, the snap-fit features were redesigned, the handle was modified and ultrasonic energy directors were added for sonic welding of parts in final assembly.

Summary

As rapid prototyping and rapid tooling technologies become more sophisticated, the importance of picking the correct technology for product applications can be critical to gaining a competitive edge. As 3M found, a combination of RP and RT technologies and materials helped them save money, speed development time and establish a foothold in the marketplace.

Owner of Mold Making Technology

Advisor to Rapid Tooling

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Although the term rapid is relative, the reason why the term is used in this process is because prior to this invention, prototypes were produced longer and with more difficulty. Not to mention that in the past, automated prototyping were limited to certain manufacturing industries. Now with rapid prototyping technology in place, a much wider application of the process is utilized, including the medical industry.

Rapid medical prototyping technology is used for things such as prototypes for medical devices and models such as anatomical parts for medical applications. Basically, what rapid prototyping in the medical industry does is that it provides the innovative avenue for doctors and medical designers as well as patients, generate a physical representation of their design so that they can test its usability.

Of course because these rapid prototypes will be used for the medical industry, it is important to contract a prototyping solutions provider that is quick and reliable and who will only use FDA approved materials. You will also want a prototyping solutions provider who you can trust with confidential information.

What has to be the most exciting contribution of rapid prototyping in the medical industry is the fact that RP technology has gone beyond providing sample models so that doctors and patients can test the shape and feel of these products. Now, through rapid medical prototyping, models of human bone, tissue and other anatomical parts are available for use by surgeons to study strategies for complex surgery.

The rapid prototyping technology used for the medical industry is relatively new. This is why there are many new and exciting discoveries for applications of this RP technology. It is definitely revolutionizing the way medicine is practiced. These medical prototypes are helping medical practitioners to be of better service to patients without the long turn over or risks in experimentation.

Having actual prototypes of anatomical parts help not only doctors to better understand and discuss strategies, but it also helps for doctors in explaining complex procedures to their patients with the use of these aids. While 3D computer images used to in the actual prototypes place, there is no doubt that rapid prototyping in the medical industry has given more depth to the practice.

Low Jeremy maintains http://prototyping.articlesforreprint.com This content is provided by Low Jeremy. It may be used only in its entirety with all links included.

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Rapid prototyping technology or RP refers to the automated construction of prototypes. Usually, the process involves, a computer aided design, which is fed into a machine, which is in turn transformed into a physical, 3D model through an automated mechanical process.

Although the term rapid is relative, the reason why the term is used in this process is because prior to this invention, prototypes were produced longer and with more difficulty. Not to mention that in the past, automated prototyping were limited to certain manufacturing industries. Now with rapid prototyping technology in place, a much wider application of the process is utilized, including the medical industry.

Rapid medical prototyping technology is used for things such as prototypes for medical devices and models such as anatomical parts for medical applications. Basically, what rapid prototyping in the medical industry does is that it provides the innovative avenue for doctors and medical designers as well as patients, generate a physical representation of their design so that they can test its usability.

Of course because these rapid prototypes will be used for the medical industry, it is important to contract a prototyping solutions provider that is quick and reliable and who will only use FDA approved materials. You will also want a prototyping solutions provider who you can trust with confidential information.

What has to be the most exciting contribution of rapid prototyping in the medical industry is the fact that RP technology has gone beyond providing sample models so that doctors and patients can test the shape and feel of these products. Now, through rapid medical prototyping, models of human bone, tissue and other anatomical parts are available for use by surgeons to study strategies for complex surgery.

The rapid prototyping technology used for the medical industry is relatively new. This is why there are many new and exciting discoveries for applications of this RP technology. It is definitely revolutionizing the way medicine is practiced. These medical prototypes are helping medical practitioners to be of better service to patients without the long turn over or risks in experimentation.

Having actual prototypes of anatomical parts help not only doctors to better understand and discuss strategies, but it also helps for doctors in explaining complex procedures to their patients with the use of these aids. While 3D computer images used to in the actual prototypes place, there is no doubt that rapid prototyping in the medical industry has given more depth to the practice.

About The Author

Rapid prototyping is a revolutionary and powerful technology with wide range of applications. The process of prototyping involves quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance. The user is able to give immediate feedback regarding the prototype and its performance. Rapid prototyping is essential part of the process of system designing and it is believed to be quite beneficial as far as reduction of project cost and risk are concerned.

Rapid prototyping is known by many terms as per the technologies involved, like SFF or solid freeform fabrication, FF or freeform fabrication, digital fabrication, AFF or automated freeform fabrication, 3D printing, solid imaging, layer-based manufacturing, laser prototyping and additive manufacturing.

History of Rapid Prototyping:

Sixties: The first rapid prototyping techniques became accessible in the later eighties and they were used for production of prototype and model parts. The history of rapid prototyping can be traced to the late sixties, when an engineering professor, Herbert Voelcker, questioned himself about the possibilities of doing interesting things with the computer controlled and automatic machine tools. These machine tools had just started to appear on the factory floors then. Voelcker was trying to find a way in which the automated machine tools could be programmed by using the output of a design program of a computer.

Seventies: Voelcker developed the basic tools of mathematics that clearly describe the three dimensional aspects and resulted in the earliest theories of algorithmic and mathematical theories for solid modeling. These theories form the basis of modern computer programs that are used for designing almost all things mechanical, ranging from the smallest toy car to the tallest skyscraper. Volecker’s theories changed the designing methods in the seventies, but, the old methods for designing were still very much in use. The old method involved either a machinist or machine tool controlled by a computer. The metal hunk was cut away and the needed part remained as per requirements.

Eighties: However, in 1987, Carl Deckard, a researcher form the University of Texas, came up with a good revolutionary idea. He pioneered the layer based manufacturing, wherein he thought of building up the model layer by layer. He printed 3D models by utilizing laser light for fusing metal powder in solid prototypes, single layer at a time. Deckard developed this idea into a technique called “Selective Laser Sintering”. The results of this technique were extremely promising. The history of rapid prototyping is quite new and recent. However, as this technique of rapid prototyping has such wide ranging scope and applications with amazing results, it has grown by leaps and bounds.

Voelcker’s and Deckard’s stunning findings, innovations and researches have given extreme impetus to this significant new industry known as rapid prototyping or free form fabrication. It has revolutionized the designing and manufacturing processes.

Though, there are many references of people pioneering the rapid prototyping technology, the industry gives recognition to Charles Hull for the patent of Apparatus for Production of 3D Objects by Stereolithography. Charles Hull is recognized by the industry as the father of rapid prototyping.

Present-day Rapid Prototyping: Today, the computer engineer has to simply sketch the ideas on the computer screen with the help of a design program that is computer aided. Computer aided designing allows to make modification as required and you can create a physical prototype that is a precise and proper 3D object.

About The Author

Ryan Rounds

What is Stereolithography?
Stereolithography has many names and few of them are 3D layering, 3D printing, solid free-form fabrication, photo-solidification and solid imaging. It is the most common and extensively used form of rapid manufacturing and rapid prototyping. Stereolithography fabricates 3D parts and allows creating solid 3D objects from CAD models with high precision and excellent surface finish within few hours (time depends upon size and complexity). Machines used for Stereolithography are known as Stereolithography Apparatus (SLA).

Advantages and Disadvantages:
Stereolithography provides a quick and simple means to convert CAD models into real objects. This is very useful where time is money. The constraint as mentioned above is that the time to produce three dimensional parts depends upon the size and complexity of the object. The accuracy is very good having tolerance within .004″/inch. The problem again is that SLA devices or machines are too expensive. Photo-curable resin used in Stereolithography can cost as high as $800 per gallon. Then the process involved in SLA produces fumes due to which it requires a well ventilated environment

Best Part of Rapid Prototyping:
Since 1986, the year of its invention, SLA has taken large steps equally in its machine design and resources used for it. SLA is real rapid modeling and is fast switching from rapid prototyping to rapid manufacturing. It can be an exceptionally convenient and valuable process in many conditions and for many industries. It has been used effectively to aid surgeons with ear implants and can be used in almost every industry from jewellery manufacturing to military, power, marine etc. This makes it the best part of rapid prototyping.

About The Author

Jon T Smith