3.

5 - Rapid Prototyping
With an increase in the development of computers, computer-aided manufacture (CAM) has
become much more efficient. Models can know be designed, changed, and tested virtually
without ever needing to constantly producing prototypes to test and help visualize the changes
that can be made to improve the final product. In addition to that, we now have larger access to
a variety of materials as well as a variety of methods of production.

Rapid prototyping and RP Machines

- Rapid prototyping machines (RP machines) are essentially machines that can produce a
complete prototype of a product with both external and internal details, at a fairly quick
rate.
- By using RP machines, product development time can be decreased as the time taken
for an RP machine to make a prototype compared to that of a person making the
prototype by hand is much faster. In addition to that, by using RP machines to make
prototypes, less skill in terms of the production of the prototype is required as RP
machines are much more efficient that humans and people require less training when it
comes to operating the machines.
- Different prototypes can be manufactured for different situations. For example, if you
wish to show the client the external and internal structure of the product in clarity, you
would be able to do so as RP machines are able to create prototypes in amazing detail.
Therefore, by using RP machines you are able to communicate with your client
regarding the client more efficiently as they would be able to comprehend and RP
prototype more.

RP Process
The RP process is actually quite simple. Below is the process of RP using a 3D printer.

- First the prototype is designed on a CAD (Computer-Aided Design) software, like

Autodesk Fusion.
 - Once a full scale model is produced, the CAD file is converted to STL (Standard Triangle
Language and Standard Tessellation Language). STL is the only file format that is
recognized and read by 3D printers.
- Once the STL file has been sent to the 3D printer, the printer will begin to print the
product.
- Once the item is fully manufactured by the 3D printer, the prototype will have to been
cleaned as there will be bits and pieces of plastic sticking out of the prototype (depends
on how the prototype was printed)

Stereolithography (SLA)
Stereolithography (SLA) is a 3D printing/additive process
- It is consists the usage of photosensitive resin and a vertically moving platform. As well
as an ultraviolet laser.
- The machine works by receiving the STL data from a CAD software. Then the
photosensitive resin is placed on top of the platform.
- An ultraviolet light which is located at the top of the SLA machine and is controlled by a
series of mirrors, is beamed onto the resin.
- The laser traces out the image on the resin. As soon as the laser comes into contact
with the resin, it hardens on impact. Once one layer is down, the platform moves down
and a sweeper ensures there is fresh resin on top so that the next layer can be
hardened.
- This RP process is used for producing models and prototypes

Laminated Object Manufacturing (LOM)

- Laminated Object Manufacturing (LOM) works by taking the slice CAD data from the
STL file and cutting each layer from a roll of material.
 - The roll of material is rolled onto a platform. A laser on top of the machine cuts the sliced
part and is controlled by mirrors located on the top of the machine as well.
- Once a layer is cut, rollers on the side of the machine pull the waste material into a roll
and pull out fresh material in order for the next layer to be cut.
- Once each layer is cut, it is glued together.

Fused Deposition Modelling (FDM)

Fused Deposition Modelling (FDM) is a layer additive manufacturing process
- First, the CAD data is sent to the FDM machine. The machine then begins to construct
the product layer by layer.
- Thin thread-like spools of thermoplastic are used to create the part. The spools of
thermoplastic is heated in a similar manner of that of a glue gun. Once the thermoplastic
has been sufficiently melted, it is then extruded out of nozzle and each layer of the part
is constructed.
- The thermoplastic used is normally ABS.
- The extrusion nozzle moves in horizontal plane, while the build platform moves on a
vertical plane so that each layer can be built.
- FDM is very useful for creating concept models, functional prototypes and low-volume
end-use parts.
Selective Laser Sintering (SLS)
Selective Laser Sintering (SLS) is an additive manufacturing process.
- When the STL data is sent to the SLS machine, the machine begins production on the
first layer.
- SLS uses materials such as powdered nylon 11, nylon 12 and PEEK materials. Once a
layer thickness is placed on the build platform, a CO2 laser located on the top of the
machine heats up the powdered nylon that it hardens together.
- Once the first layer is complete, the build platform will drop a layer thickness so that the
next layer can begin. In addition to that, fresh powder is deposited on the build platform
after each layer is built.
Advantages and Disadvantages of RP Techniques
Advantages
- More intricate product design can be made
- Prototypes with amazing detail can be produced quickly
- Functional prototypes can even be made
- Decrease in the development time of products
- Changes can be easily made due to the fact that new prototypes can be made with ease
and in short time
- Reduce in costs of the production of prototypes as well as reduces the risk of large
mistakes being made due to the efficiency and accuracy of machines
- Prototypes can be made to be as complex as the final product itself
- Less waste is generated in the process as well as less material is wasted than what
would have been wasted if the prototype had been made by hand
- A larger range of materials can be used, which can help make the prototype as close to
the final product as possible as well being able to use cheaper materials that would not
have been usable had the prototype been made by hand
- By making more detailed prototypes, communication between clients and designers is
much more efficient
Disadvantages
- While RP production is much faster than if the prototype was made by hand, the process
can still take many hours in order to complete as things like the raft of the prototype as
well as the supports built during the process can be left over and take a while to clear
- It is not suitable for making multiple prototypes in a short amount of time as the time
taken to make and clean one prototype takes a significant amount of time. (not suitable
for batch or mass production) (also the internal structure of many of the prototypes
produced by RP production takes a lot of time to construct)
- Due to the fact that many of the RP production methods have very small build platforms,
the size of the prototype produced is limited. Therefore, large prototypes is not suitable
for RP production in terms of efficiency as multiple components would have to be
constructed in the process and then assembled later, which would take time, thus
defeating the purpose of RP production which is meant to decrease the time needed on
the production of prototypes.