What is Rapid Prototyping ?
Rapid prototyping (RP) technology is used for building physical
models and prototype parts straight from 3D CAD model, which is
sectioned into many thin horizontal slices and data is passed
to RP systems that join together liquid, powder and sheet materials
to form complex parts layer by layer.
What is FDM?
FDM also known as Fused Deposition Modeling is layered manufacturing
process. FDM offers functional prototypes with ABS, and other
materials. A thin bead of molten plastic is extruded through the
computer controlled nozzle, which is deposited on a layer-by-layer
basis to construct a prototype directly from 3D CAD data. The
technology is commonly applied to form, fit and function analysis
and concept visualisation. In addition, FDM can be used for pattern
generation and rapid manufacturing.
What is 3d Printing ?
3d Printing is the less costly process of rapid prototyping
which turns the 3D CAD data to quickly produce a three dimensional
model for conceptual evaluation. Where an ordinary printer lays
down a single 2D layer of ink on a sheet of paper, these printers
add the extra dimension by printing layer after layer until you
have a real, 3d object similar to your CAD model. Manufacturers
report enormous productivity gains from using 3d printed parts.
What is SLA?
SLA also known as "Stereolithography",
provides the greatest accuracy with an excellent surface finish.
SLA parts are durable and these functional parts are suitable
for wide variety of applications e.g. pre production, Product
verification, Form/Fit/function testing, Snap fit assemblies,
thin walled parts. Please check our SLA
specification page for detailed information.
How SLA Process works?
Stereolithography process produces plastic parts directly
from 3D CAD model; by solidifying the surface of a liquid photo
polymer layer by layer with the help of a laser beam. When the
laser beam hits the liquid, it solidifies the resin. When a layer
is fully traced, the elevator is then lowered in the vat. The
self-adhesive property of the material causes the layer to stick
with each other and in this way a 3d part is formed in multi-layers.
What is SLS?
SLS also known as "Selective Laser Sintering",
primarily used to quickly produce three -dimensional prototypes,
parts, direct mold inserts, tools, and lost wax casting patterns.
SLS process provides durable, metal, plastic or rubber like prototypes
directly from CAD model. These prototypes can be used as test
parts for form, fit and function. SLS technology provides broad
range of materials e.g. rigid thermoplastics, stainless steel,
polystyrene, thermoplastic elastomers, cast form plastic for investment
castings. Please check our SLS
specification page for detailed information.
How SLS Process works?
SLS process produces parts directly from 3D CAD model; layer by
layer similar to SLA but rather than liquid resin powder is used.
The CO2 Laser provides a concentrated heating beam which is traced
over the tightly compacted layer of fine heat-fusible powder.
The temperature in the entire chamber is maintained little below
the melting point of the powder. So laser slightly raises the
temperature to cause sintering, means welding without melting.
For next level, piston moves down along with the formed object
and powder is spread with a roller for next layer. Process repeats
until full object is formed.
What are the main applications
of Rapid Prototyping?
Although there is a big listing of prototyping applications. This
technology is maturing rapidly specially in automotive, medical,
toys building, packaging, aerospace, electrical, scientific applications
and so on.
Few examples here :
a) Imagine there is a major exhibition next week and your
new product is still in development stage, How to get the part
urgently? just send us your CAD file rest is up to us to meet
your deadline.
b) Why to take a risk of getting unrealistic quotes from
your suppliers by sending 2d drawings, when you can send inexpensive
3d physical part which will not only help to save money at the
end but also helps to open new options to manufacture the part
or tooling.
c) Manufacturers who need parts in small quantities where
tooling or production cost is not justified.
d) Sometimes it is difficult for the designers or toolmakers
to visualize or find out the problems in the drawings, by having
the 3d part in their hands, helps them to figure out the problem
and redesign it if required before investing on actual tooling.
e) Helps the medical field in many different ways specially
for reconstructive surgery by making 3d models created from CT
scan of the patient's body parts.
f) Quickly making master model for vacuum casting to produce
small quantity of Poly Urethane parts.
g) If you are a student, scientist, teacher and you need
to make a part for your next project or class demonstration, what
to do? Rapid prototyping is the quick answer for you.
h) Building my new home but like to see how the design
will look like in real life.
i) To make some Artistic or unique design for example statue,
jewelry, special type of toy even some part is broken of your
home appliance which is not easily available in the market.
j) Any spare parts or auto part hard to find in the market.
k) Tooling inserts for plastic injection moulding direct
in steel able to produce thousands of parts.
l) For further applications and material details please
follow Specifications
link
How much it will cost
to make a prototype ?
Prototyping cost varies according to material and process selection.
Generally 3d printed parts are lot cheaper to make than other
RP processes. Some companies saved millions of dollars by spending
few hundreds on 3d prototypes. For more about price information
follow our QUOTES page.
I got an idea what I want but
don't have a CAD model, what to do ?
There are many CAD service bureaus able to help you otherwise
contact us for all your CAD work needs we'll be more than happy
to provide you the best service available in the market.
Can you make functional prototypes
?
It really depends upon the functionality of the product you want
to achieve. We have various technologies available, to make functional
parts e.g. FDM & SLS and CNC machining direct on industrial
materials. Please check specifications
and applications of different materials. Sometimes we machine
prototypes from solid block of metal or plastic block to get the
maximum strength when demanded.
What
is STL format and how I can export from CAD package ?
An STL file is simply a mesh of triangles
wrapped around a CAD model was defined by 3D systems in 1980s.
STL, name is derived from rapid prototyping process, StereoLithography,
also known as abbreviation of Standard Triangulation
Language. This very simple format has become
an industry standard for the Rapid Prototyping sector. Virtually
all modern CAD systems now include STL or Rapid Prototyping output
as a standard feature.
Please check this link for further detail
STL- Specs
What about the part
surface finish after finishing ?
Normally all prototyping processes require post processing operation
to give a smooth finish. SLA process still gives much better finish
than 3D printing and SLS process. Normally parts are finished
with standard finish; means outer or visible faces are lightly
sanded and internal features are left machine finish. But surface
finish can be further improved by fine sanding, polishing or painting
which is only done upon special request from customer and increases
the prototype cost. These prototypes can be even further machined
or drilled as a secondary operation.
How long it takes to
make a part ?
It could be few hours or a day it really depends upon the build
size, shape and accuracy needed. 3D printing is reputed as a very
fast and efficient technology in RP industry. Standard lead time
for 3D printed parts is 1 to 2 days in Australia.
What is the maximum size
limit of the part ?
Please check services
link for maximum limit size for different processes, but if your
part is larger than the build range we can easily split in sections
and glue them together. This is common practice for large size
prototypes.
What other services do
you provide ?
We provide full range of Prototyping service, using our in-house
facilities and network of partners. Some of services we provide
3D printing, SLA, SLS, FDM, CNC machining, Vacuum Casting, Investment
casting, Sheet Metal parts and tooling, CAD/CAM service. Lately
we started our new division of Architectural modeling. For more
information please visit or Services
section.
