Home Discussion Topics Dictionary Almanac

Signup Login

Rapid prototyping

Overview

Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. The first techniques for rapid prototyping became available in the late 1980s and were used to produce model

Model (physical)

A physical model is a smaller or larger physical copy of an object. The object being modelled may be small or large ....

s and prototype

Prototype

A prototype is an original type, form, or instance of something serving as a typical example, basis, or standard for other things of the same category...

parts. Today, they are used for a much wider range of applications and are even used to manufacture production-quality parts in relatively small numbers. Some sculptors use the technology to produce complex shapes for fine arts exhibition

Exhibition

Exhibition may refer to:*Exhibition , a sport involving horses and riders*Exhibition game, a friendly match*Exhibition hall, where exhibitions are held*Exhibition , a financial award to scholars...

s.

The use of additive manufacturing technology for rapid prototyping takes virtual designs from computer aided design (CAD) or animation

Animation

Animation is the rapid display of a sequence of images of 2-D or 3-D artwork or model positions in order to create an illusion of movement. It is an optical illusion of motion due to the phenomenon of persistence of vision, and can be created and demonstrated in a number of ways...

modeling software, transforms them into thin, virtual, horizontal cross-sections and then creates successive layers until the model is complete.

Discussion

Ask a question about 'Rapid prototyping'

Start a new discussion about 'Rapid prototyping'

Answer questions from other users

Full Discussion Forum

Encyclopedia

Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. The first techniques for rapid prototyping became available in the late 1980s and were used to produce model

Model (physical)

A physical model is a smaller or larger physical copy of an object. The object being modelled may be small or large ....

s and prototype

Prototype

A prototype is an original type, form, or instance of something serving as a typical example, basis, or standard for other things of the same category...

parts. Today, they are used for a much wider range of applications and are even used to manufacture production-quality parts in relatively small numbers. Some sculptors use the technology to produce complex shapes for fine arts exhibition

Exhibition

Exhibition may refer to:*Exhibition , a sport involving horses and riders*Exhibition game, a friendly match*Exhibition hall, where exhibitions are held*Exhibition , a financial award to scholars...

s.

Introduction

The use of additive manufacturing technology for rapid prototyping takes virtual designs from computer aided design (CAD) or animation

Animation

Animation is the rapid display of a sequence of images of 2-D or 3-D artwork or model positions in order to create an illusion of movement. It is an optical illusion of motion due to the phenomenon of persistence of vision, and can be created and demonstrated in a number of ways...

modeling software, transforms them into thin, virtual, horizontal cross-sections and then creates successive layers until the model is complete. It is a WYSIWYG

WYSIWYG

WYSIWYG , is an acronym for What You See Is What You Get. The term is used in computing to describe a system in which content displayed during editing appears very similar to the final output, which might be a printed document, web page, slide presentation or even the lighting for a theatrical...

process where the virtual model and the physical model are almost identical.

With additive manufacturing, the machine reads in data from a CAD drawing and lays down successive layers of liquid, powder, or sheet material, and in this way builds up the model from a series of cross sections. These layers, which correspond to the virtual cross section from the CAD model, are joined together or fused automatically to create the final shape. The primary advantage to additive fabrication is its ability to create almost any shape or geometric feature.

The standard data interface

Interface (computer science)

Interface generally refers to an abstraction that an entity provides of itself to the outside. This separates the methods of external communication from internal operation Interface generally refers to an abstraction that an entity provides of itself to the outside. This separates the methods of...

between CAD software and the machines is the STL file format

STL (file format)

STL is a file format native to the stereolithography CAD software created by 3D Systems. This file format is supported by many other software packages; it is widely used for rapid prototyping and computer-aided manufacturing. STL files describe only the surface geometry of a three dimensional...

. An STL file approximates the shape of a part or assembly using triangular facets. Smaller facets produce a higher quality surface.

The word "rapid" is relative: construction of a model with contemporary methods can take from several hours to several days, depending on the method used and the size and complexity of the model. Additive systems for rapid prototyping can typically produce models in a few hours, although it can vary widely depending on the type of machine being used and the size and number of models being produced simultaneously.

Some solid freeform fabrication

Solid freeform fabrication

Solid freeform fabrication is a collection of techniques for manufacturing solid objects by the sequential delivery of energy and/or material to specified points in space to produce that solid...

techniques use two materials in the course of constructing parts. The first material is the part material and the second is the support material (to support overhanging features during construction). The support material is later removed by heat or dissolved away with a solvent or water.

Traditional injection molding

Injection molding

Injection molding is a manufacturing process for producing parts from both thermoplastic and thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools and hardens to the configuration of the mold cavity...

can be less expensive for manufacturing polymer products in high quantities, but additive fabrication can be faster and less expensive when producing relatively small quantities of parts. 3D printers give designers and concept development teams the ability to produce parts and concept models using a desktop size printer.

Rapid prototyping is now entering the field of rapid manufacturing

Rapid manufacturing

Rapid manufacturing is an additive fabrication technique for manufacturing solid objects by the sequential delivery of energy and/or material to specified points in space to produce that part. Current practice is to control the manufacturing process by computer using a mathematical model created...

and it is believed by many experts that this is a "next level" technology.

Technologies

A large number of competing technologies are available in the marketplace. As all are additive technologies, their main differences are found in the way layers are built to create parts. Some are melting or softening material to produce the layers (SLS

Selective laser sintering

Selective laser sintering is an additive manufacturing technique that uses a high power laser to fuse small particles of plastic, metal , ceramic, or glass powders into a mass representing a desired 3-dimensional object...

, FDM

Fused deposition modeling

Fused deposition modeling is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. The technology was developed by S. Scott Crump in the late 1980s and was commercialized in 1990...

) where others are laying liquid materials thermosets that are cured

Curing (chemistry)

Curing is a term in polymer chemistry and process engineering that refers to the toughening or hardening of a polymer material by cross-linking of polymer chains, brought about by chemical additives, ultraviolet radiation, electron beam or heat...

with different technologies. In the case of lamination systems, thin layers are cut to shape and joined together.

As of 2005, conventional rapid prototype machines cost around £25,000.

Prototyping technologies	Base materials
Selective laser sintering Selective laser sintering Selective laser sintering is an additive manufacturing technique that uses a high power laser to fuse small particles of plastic, metal , ceramic, or glass powders into a mass representing a desired 3-dimensional object... (SLS)	Thermoplastics, metals powders
Fused deposition modeling Fused deposition modeling Fused deposition modeling is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. The technology was developed by S. Scott Crump in the late 1980s and was commercialized in 1990... (FDM)	Thermoplastics, eutectic metals.
Stereolithography Stereolithography Stereolithography is an additive manufacturing technology for producing models, prototypes, patterns, and in some cases, production parts.-Technology description:... (SLA)	photopolymer Photopolymer A photopolymer is a polymer that cures, or becomes solid, when exposed to light, often in the ultraviolet spectrum. These polymers are useful in dentistry for fillings and in rapid prototyping in the stereolithography and 3D printing processes. This material is also used in the creation of ADA...
Laminated object manufacturing Laminated object manufacturing Laminated object manufacturing is a rapid prototyping system developed by Helisys Inc. In it, layers of adhesive-coated paper, plastic, or metal laminates are successively glued together and cut to shape with a knife or laser cutter.The process is performed as follows:# Sheet is adhered to a... (LOM)	Paper Paper Paper is thin material mainly used for writing upon, printing upon or for packaging. It is produced by pressing together moist fibers, typically cellulose pulp derived from wood, rags or grasses, and drying them into flexible sheets....
Electron beam melting Electron Beam Melting Electron beam melting is a type of additive manufacturing for metal parts. It is often classified as a rapid manufacturing method. The technology manufactures parts by melting metal powder layer per layer with an electron beam in a high vacuum... (EBM)	Titanium alloy Titanium alloy Titanium alloys are metallic materials which contain a mixture of titanium and other chemical elements. Such alloys have very high tensile strength and toughness , light weight, extraordinary corrosion resistance, and ability to withstand extreme temperatures... s
3D printing 3D printing 3D printing is a form of additive manufacturing technology where a three dimensional object is created by successive layers of material. 3D printers are generally faster, more affordable and easier to use than other additive manufacturing technologies... (3DP)	Various materials

Rapid prototyping

Introduction

Technologies

See also