Rapid prototyping is the automatic and quick-turn construction of
physical objects. This type of prototyping has been developed as an
outgrowth of liquid photopolymer research. Early rapid prototyping (RP)
used machines called SLA's (Stereo Lithography Apparatus). More
recently, another approach called FDM (Fused Deposition Modeling) makes
use of a heated nozzle to extrude plastic onto the work piece. Fused
Deposition Modeling led to the use of a wider range of materials
including polycarbonates, ABS and other plastics. Fused plastic is
deposited layer by layer according to the 3D model.
Numerous shapes are
possible with a rapid prototyping machine.
A prototyping machine takes virtual designs from computer aided design
(CAD) software, transforms them into cross sections and later creates
each cross-section in sequence, one after the next until the model is
completely finished. It is a WYSIWYG ("what you see is what you get")
process where the virtual model and the physical model align. The rapid
prototyping machine reads data from a CAD drawing and lays down
successive layers of liquid or powdered material, creating the model
from a series of cross sections. These layers, derived from the CAD
model, are fused together automatically to create the final shape. The
primary advantage to additive construction is its ability to create
almost any geometry and patterns.
www.eMachineShop.com advises designers to observe an important design
constraint in prototype design - since the FDM extrusion is generally
.010" wide, it is best to keep dimensions in multiples of this value -
especially smaller dimensions (including material, air, diameters,
etc.).
With the advent of rapid prototyping machines it is now possible for
eMachineShop CAD software to output directly to a rapid prototyping
machine. Importantly, eMachineShop keeps the run costs low since rapid
prototyping does not require tooling; short production runs can be made
at lower cost and faster turnaround. This approach also provides higher
confidence when committing to conventional tooling. Rapid prototyping
helps engineers, designers and end users check designs for usability,
appearance and manufacturability. Rapid prototype machines help to
speed up the new product design cycle.
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