Why Do You Need the Services of a Rapid Prototyping Company?
Any product development in the world requires a prototype. The project may be of any size you can imagine, but nothing can go to production based on a concept. You need to make sure that your idea is functional and a rapid prototyping company can do that for you in a matter of moments.
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Rapid prototyping as service costs money. Even if you are crafty enough to bring a proof of concept on your own, you need modern technology to make sure it works the way it&#;s supposed to. A part of your budget should be destined to the creation of a new prototype using automated means such as 3D printing.
One of the things that no one tells you is that if you only have a slight idea about your product. A rapid prototyping company has a team that can help you make your vision a reality for very little money and in a short time. Your rough ideas no longer need a separate designer since most of these companies have in-house design teams to create your prototype from scratch.
Rapid prototyping is suitable for entrepreneurs developing original equipment pieces. It works if they need a high-quality prototype in a narrow window of time to secure funding or to keep the costs of the budget at bay. You need these services because there has never been a better moment in the manufacturing industry to get ahead with your creations using these companies.
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When Should You Use the Services of a Rapid Prototyping Company?
Rapid prototyping is the best fit to create plastic parts with precision. To achieve a good streak of usable products, you need to work with a team of people who knows what they are doing. Any rapid prototyping company worth their salt has a team of engineers and product developers to test your product and fix any issue on the go.
Think for a minute about all the products that require a perfect fit. It can be anything from protective gear for workers to a little moving part that goes inside a larger machine. Every single one of these products can be created using these services. If your project requires manufacturing, that&#;s when you should consult a company about a quote to get things done.
This is probably the trickiest question in the list because not all projects are meant to be developed by the same standards. If we consider complexities, a small piece no bigger than the sections of your hand can cost from $80 to $1,200. Small parts that require no post-production polishment sit on the low end of this spectrum. Components that require sanding or painting will cost a lot more.
What is the Most Popular Software used for Rapid Prototyping Projects?
The software program used to print prototypes is developed exclusively to work with the machines of the rapid prototype company of your choice. The developing software is another story since most companies use one of the following to create their CAD models: AutoCAD, Autodesk Inventor, Fusion360, Mastercam, Pro-E, or Pro/Engineer, or Solidworks.
Is it Possible to Create Rapid Prototypes Using Injection Molding Technology?
Injection molding is a process that can be used to create prototypes but also to mass produce any product. It&#;s the best expression of having your cake and eating it too. The most obvious advantage is the possibility to create a prototype, just the same way the product will be created. You only need to create a cavity mold that can process molten plastic to be injected and cooled to make a solid piece.
If you compare this method with 3D printing, you will realize how easily plastic injection molding can create higher-quality surface finishes. The amount of detail is extended to other features such as noticeable square holes, and living hinges. Other little bits that can be created using other manufacturing methods such as CNC machining. The only drawback of this method is the amount of time required to create the mold, as well as the overall cost of it.
After you are done with the stage, testing out the prototype should be a breeze. Remember to use it to evaluate everything regarding the specs of your project, such as the quality of the material used as well as the cosmetic finishes of the final product.
What You Should Look for in a Rapid Prototyping Company
Regardless of the location of your rapid prototyping company of choice, you need to pay attention to some details regarding your chosen service provider. Doing your homework on them will pay off for good on your end. Do an internet search on them, check for their reputation. Check if they have a consistent track record fulfilling the needs of their customers, see how quick they answer to your concerns. Make sure to check their prices against their competitors.
Definitions
Definitions vary and may differ at different organizations, but the definitions below may be used as a starting point.
Concept Model: a physical model made to demonstrate an idea. Concept models allow people from different functional areas to see the idea, stimulate thought and discussion, and drive acceptance or rejection.
Prototyping Attributes
Speed: turnaround time to convert a computer file into a physical prototype
Appearance: any visual attribute: color, texture, size, shape, etc.
Assembly/Fit Testing: making some or all of the parts of an assembly, putting them together, and seeing if they fit properly. At the gross level, this checks for design errors, such as placing two tabs at 2 in. spacing and the mating slots at 1 in. spacing. At the fine level, this is a matter of minor dimensional differences and tolerances. Obviously, any test involving tolerances needs to use the actual manufacturing process or one which has similar tolerances.
Prototyping Attributes
Form: the shape of the part: features and size
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Fit: how the part mates with other parts
Functional Testing: seeing how a part or assembly will function when subjected to stresses representing what it will see in its actual application.
Prototyping Attributes
Chemical Resistance: resistance to chemicals including acids, bases, hydrocarbons, fuels, etc.
Mechanical Properties: strength of the part measured by tensile strength, compressive strength, flexural strength, impact strength, tear resistance, etc.
Electrical Properties: interaction of electrical fields and the part. This may include dielectric constant, dielectric strength, dissipation factor, surface and volume resistance, static decay, etc.
Thermal Properties: changes in mechanical properties that occur with changes in temperature. These may include thermal expansion coefficient, heat deflection temperature, vicat softening point, etc.
Optical Properties: ability to transmit light. May include refractive index, transmittance, and haze.
Life Testing: testing properties that may change with time and that are important for a product to remain functional throughout its expected life. Life testing often involves subjecting the product to extreme conditions (e.g., temperature, humidity, voltage, UV, etc.) to estimate in a shorter period of time, how the product will react over its expected life.
Prototyping Attributes
Mechanical Properties (fatigue strength): ability to withstand large numbers of load cycles at various stress levels.
Aging Properties (UV, creep): ability to withstand exposure to ultraviolet light with an acceptable amount of degradation; ability to withstand extended applications of forces to the part with acceptable levels of permanent deflection.
Regulatory Testing: testing specified by a regulatory or standards organization or agency to assure parts are suitable for a particular use such as medical, food service or consumer application. Examples include Underwriters Laboratory (UL), the Canadian Standards Association (CSA), the U.S. Food and Drug Agency (FDA), the U.S. Federal Communications Commission (FCC), the International Standard Organization (ISO) and the European Commission (EC).
Prototyping Attributes
Flammability Properties: the resistance of a resin or part to ignition in the presence of a flame.
EMI/RFI Properties: the ability of a resin, part or assembly to shield or block Electromagnetic Interference or Radio Frequency Interference.
Food Rating: approval of a resin or part to be used in applications where it will come in contact with food while it is being prepared, served or consumed.
Biocompatibility: the ability of the resin or part to be in contact with human or animal bodies, outside or inside the body, without causing undue adverse effects (e.g., irritations, blood interactions, toxicity, etc). Biocompatibility is important for surgical instruments and many medical devices.
Summary
Prototype models help design teams make more informed decisions by obtaining invaluable data from the performance of, and the reaction to, those prototypes. The more data that is gathered at this stage of the product development cycle, the better the chances of preventing potential product or manufacturing issues down the road. If a well thought out prototyping strategy is followed, there is a far greater chance that the product will be introduced to the market on time, be accepted, perform reliably, and be profitable.
What is the best way to get a prototype made? The answer depends on where you are in your process and what you are trying to accomplish. Early in the design process, when the ideas are flowing freely, concept models are helpful. As the design progresses, a prototype that has the size, finish, color, shape, strength, durability, and material characteristics of the intended final product becomes increasingly important. Therefore, using the right prototyping process is critical. In order to most effectively validate your design, pay close attention to these three key elements of your design: functionality, manufacturability, and viability.&#;
If your prototype can faithfully represent the attributes of the end-product, it is by definition functional.&#;These requirements often include such things as material properties (e.g., flame resistance), dimensional accuracy for fit-up with mating parts, and cosmetic surface finishes for appearance.
If your prototype design can be repeatedly and economically produced in a manner that supports the requirements of the end product, it is by definition manufacturable.&#;These requirements include the ability to maintain the functionality of the design as described above, keep the piece-part cost below the required level, and support the production schedule. No matter how great a design is, it will go nowhere if it can&#;t be manufactured. Make sure your prototyping process takes this into consideration.
Finally, even if your prototype design is functional and manufacturable, it doesn&#;t mean anyone will want to use it.&#;Prototypes are the only true way to verify the viability of the design in this sense.&#;If your design can also pass the challenges associated with market trials (e.g., trade show displays, usability testing) and regulatory testing (e.g., FDA testing of medical devices), you&#;re well on your way to a successful product launch.
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