Rapid Prototyping Techniques

Introduction to Rapid Prototyping

Rapid prototyping is a group of techniques used to quickly fabricate a model of a physical part or assembly using three-dimensional computer-aided design (CAD) data.
It enables designers and engineers to illustrate ideas or concepts, and to test functionality early in the development process.
This method is highly beneficial for validating design and function while reducing the risk of costly design mistakes.

3D Printing: Utilises additive processes to create the prototype layer by layer using a wide variety of materials including plastic, resin, and metal.
Stereolithography (SLA): Produces highly accurate models by using a laser to harden liquid resin in a basin.
Selective Laser Sintering (SLS): Uses a laser to heat and solidify plastic, metal, or ceramic powder, providing the ability to create complex geometries and functional parts.
Fused Deposition Modelling (FDM): Heats and extrudes a thin filament of plastic to build an object layer by layer.
Laminated Object Manufacturing (LOM): Layers are laminated together to create a model or prototype.

Quick Feedback: It’s possible to get immediate feedback from users and apply changes as required to the design.
Minimised Design Flaws: Allows designers to verify and validate designs, thereby reducing the chance of expensive errors.
Reduced Time and Costs: Prototype production time is greatly reduced as it is all computer generated, hence, reducing the cost of labour and materials.

Limited by Materials: Prototypes created may not have the exact properties of the intended material, leading to misjudged model behaviour.
Size Limitations: Depending on the equipment, sizes of the printed models may be limited.
Post-Processing Requirements: Most parts require finishing operations like clearing away supporting materials, curing, or post-curing treatments.

Product Development: It’s used to produce prototypes of new products for demonstrations, testing and adjusting the design.
Medical Applications: Custom prosthesis, surgical guides, and anatomical models are created using rapid prototyping.
Architectural Models: Rapidly create physical models of architectural designs for client or planning approval.
Automotive Industry: Curves, designs and fixtures can be trialled in a real-world context before moving to the production phase.