A prototype is an experimental or developmental part created to represent something that is not yet a final product. It can be a tool, device, or prototype of a new product. When we talk about a prototyping process, we usually refer to various techniques, including Binder jetting, Selective laser melting, Rapid prototyping, and CNC machining. Each method has its benefits, but some common characteristics are shared across the various types.
Rapid prototyping
Rapid prototyping is an automatic process of developing a three-dimensional model of a part directly from the CAD file. This type of modeling is used for testing and improving the design. Creating prototypes helps product designers evaluate the performance of components’ performance and make material and assembly adjustments. Developing prototypes quickly and cost-effectively allows product developers to test and adjust designs before committing to full production.
Prototypes can be made using a wide range of techniques. One of the most common processes is additive manufacturing, which uses a laser beam to fuse powdered materials to form a part. Another technique is stereolithography, which uses a photosensitive liquid that solidifies layer by layer with ultraviolet light.
Stereolithography
Stereolithography is a form of rapid prototyping that allows you to make prototype parts. It is a process that uses ultraviolet light to solidify resin selectively. By using this method, you can create almost any 3-D shape.
It is a very popular way to prototype. It’s ideal for creating small, detailed, and intricate parts. You can use stereolithography to build concept models as well as prototypes for functional parts. The parts made by stereolithography have smooth, high-quality surfaces and are dimensionally accurate.
Unlike Selective Laser Sintering, Stereolithography uses light instead of heat. This helps you reduce the costs associated with building a prototype part. In addition, stereolithography also produces strong, durable objects.
Electron beam melting
Electron beam melting (EBM) is a 3D printing technique that produces fully dense, stress-relieved prototype parts directly from metal powder. EBM is a unique, additive manufacturing process with the potential to be used in a wide range of industries.
Electron beam melting is a type of powder bed fusion that uses a high-powered electron beam to selectively melt discrete layers of powder. The process is used to create parts with complex shapes and surfaces, and it has been shown to produce materials with excellent properties.
Electron beam melting has been demonstrated to work on various materials, including composites and ceramics. It is also ideal for producing orthopedic implants.
Selective laser melting
Selective laser melting (SLM) is a type of additive manufacturing technique. This method uses a high-power density laser to melt metallic powders selectively. This process produces near-net-shape parts.
German scientists in the early 1990s developed the technology. Its application was initially limited to the aerospace industry. However, new advances have enabled it to be used on various metals. In addition, the process has shown several economic benefits.
Unlike conventional additive manufacturing methods, SLM can be used to manufacture functional components with a high degree of structural integrity. As such, it is favored for producing complex, high-strength parts.
Binder jetting
Binder Jetting is a technology that can be used to produce prototype parts in a wide range of materials. In particular, binder jetting is used for prototype parts of metals and ceramics.
Binder Jetting is a 3D printing process that uses powder material to build up layers. The layer thickness is usually around 100 microns. Some binder jetting printers are equipped with secondary nozzles for dyes and pigments.
Sand is a common material for binder jetting prints. It is a relatively cheap and environmentally friendly substance. However, it can be a challenge to create beautiful prints.
CNC machining
CNC machining prototype parts is a great way to test a new product’s functionality and design, especially in today’s fast-paced design cycles. The process uses computer-aided design (CAD) files to produce a part with a proper mechanical shape.
Compared to traditional machining, CNC machining of prototype parts produces faster results. As a result, the manufacturing process becomes more cost-effective. Also, CNC machining provides higher degrees of strength and durability. This enables engineers to produce prototypes that closely resemble the final product.
The automotive industry relies on CNC machining to produce high-quality and precision-crafted parts. This process produces ultra-tight tolerances.
