Rapid Prototyping & Manufacturing Technologies - to submit your ...

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Rapid Prototyping & Manufacturing Technologiesteam composed of the marketing, design, engineering and manufacturing peopleto design right at the first instance in catering for the customers.Rapid prototyping (RP) is rapid creation of a physical model. However, rapidprototyping is slowly growing to include other areas. So, Rapid Prototyping,Tooling and Manufacturing (RP&M) should be used to include the utilization ofthe prototype as a master pattern for tooling and manufacturing.1.1 Types of prototype for NPDBefore getting involves to the topic of RP&M, the fundamental concepts andapplications of prototypes should be obtained. Prototypes that will be required inthe product design and development process are commonly divided into thefollowing types.• 3D sketches• Cosmetic prototypes• Engineering / Functional prototypes• Samples for safety approval• Marketing Samples1.1.1 3D sketchesTraditionally product designer use foam, cardboard, clay or wood to make quickmodels. The designers may generate a lot of simple model a day to visualizedifferent ideas. They also interchange portions of different models by cut andpaste, or reshape the model to explore different possibility. Since it is the earlystage of the project, usually the models are not presented to outside clients,therefore colors and textures and surface finishing are not an issue.Among various RP technologies, Multi-jet Modeling (MJM) and 3D-printing (3DP)technologies is most suitable for 3D sketches not only because they are faster, butalso because they are less expensive and the models are easier to reshape.1.1.2 Cosmetic prototypesAs the name implied, the prototypes are used to evaluate the appearance andfeeling of the design, and get early comments from potential clients. Apart fromsolid and non-functional, cosmetic prototypes are the same as finished product inaspect, such as shape, color, texture and hardness.Most RP technologies can be used for cosmetic prototypes. However, those withbetter post-processing properties will have a competitive edge because a lot ofpolishing and painting will be applied on the model. In this perspective, SLA &MJM are easier to polish because of its smooth surface. FDM is more difficultbecause the part have to be cover with a layer of putty. SLS and LOM are amongthe most difficult, due to the tough nylon material and fiber strands of paper.'Concept modelers' is the choice where time is the most critical concern. Theseinclude droplet deposition systems such as InVision, Objet and ZCorp's machine.Page 2IC Professional Training
1.1.3 Engineering / Functional prototypesRapid Prototyping & Manufacturing TechnologiesIn engineering development, Engineers will evaluate the form, fit and function ofthe parts. The prototype will use the same material of the final product iftechnology permitted. If exact material is not available, the materials with similarmechanical, thermal and electrical properties are used. The SLS and FDM allow theuse of production grade plastic material, although the mechanical properties arenot exactly the same.1.1.4 Samples for safety approvalFor those products that are regulated by safety standards of importing country, atlease 5-10 product samples have to be submitted to the laboratory for eachapplication. If pilot run of the product is ready, the finish products will besubmitted. However, in most case the project is still in tooling stage, and samplesby PU duplication may be used if the laboratory accepts. 5 to 10 duplicates can beproduced in a day. PU duplicate cannot be used as substitution if the part underconsideration is subjected to high temperature, voltage and mechanical abuse. Inthis Rapid Tooling techniques can be used. Manufacturers have a choice to quicklybuild a mould and produce a small batch of sample parts in actual productionmaterial.1.1.5 Marketing SamplesAt a later stage when all design details are finalized and the project is in toolingstage, the marketing department will start the promotion campaign. A lot ofsamples may be distributed to clients. In this case, up to a hundred products maybe needed. Normally the samples will be made by RTV mould and PU duplicationtechnique. In many cases, these models are also used to take the picture thatappears in the package box or user manual.1.2 Differences between conventional machining and rapid prototypingConventional machining can produce prototypes using metal removal methodwith almost any type of engineering materials however there are only a limitedtype of materials for any particular type of RP&M systems. RP&M systems areusually used for making one or a few sample of prototype, while the number ofprototype produced in conventional machining can be adjusted as required. Thebasic working principle of RP technologies is totally different from conventionalmachining processes which build up a solid by mean of addition approach likeconstruction of the building. Hence the RP also started from foundation thengradually increase in height until it reached the top layer.Page 3IC Professional Training
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