Rapid Prototyping Manufacturing Service

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Advantages of Rapid Prototyping

  • 60+ material selection
  • A variety of custom colors
  • Helpful for design optimization before manufacturing molds
  • Helps to understand the plastic parts that will be produced
  • Tests your design for its suitability
  • Reduces overall costs & time
  • Meets the low volume production requirement

Materials for Prototyping

Aluminium

Aluminum alloy density is low but strength is relatively high close or exceeds high-quality steel plasticity good machinability can be processed into various shapes have excellent conductivity thermal conductivity and corrosion resistance widely used in the industry compared with steel. Some aluminum alloys can obtain excellent mechanical properties physical properties and corrosion resistance by heat treatment. Hard aluminum alloy belongs to the AI-Cu-Mg series, usually contains a small amount of, heat treatment enhancement. Its characteristics are hardness, but poor plasticity. Ultra-aluminum alloy Al-1-Al-Al-O system can be enhanced by heat treatment and is the highest strength aluminum alloy at room temperature but corrosion resistance is poor and softening rapidly at high temperature. Wrought aluminum alloy is mainly an alloy of Al-Al alloy although there are many kinds of elements but few contents thus excellent thermoplastic and suitable forging.

Aluminum alloy has excellent properties such as excellent machining properties excellent weldability excellent corrosion resistance toughness high toughness non-deformation material compact non defect easy polishing film excellent oxidation effect etc.

Moderate strength good corrosion resistance good weldability good technological performance (easy extrusion forming) oxidation coloring effect is good. Application scope: architectural windows curtain wall industrial equipment frame accessories solar frame etc.

AL6061, Al6063, AL6082, AL7075, AL5052, A380。

Brass

There are two kinds of brass: ordinary brass and special brass. Brass has good plasticity and corrosion resistance, good deformability, and casting properties, and has strong application value in the industry. According to the different chemical compositions, brass can be divided into two categories: ordinary brass and special brass. The so-called ordinary brass is a copper-zinc binary alloy.

Brass can be divided into ordinary brass and special brass. In order to obtain higher strength, corrosion resistance, and good casting performance, elements such as aluminum, iron, silicon, manganese, and nickel are added to the copper-zinc alloy. Therefore, Copper alloys composed of more than two elements are called special brass.

Ordinary brass is made up of copper and zinc. According to the different content of zinc, it can be divided into single-phase brass and dual-phase brass, but the content of zinc can not exceed 45%, otherwise, the material becomes brittle and can not be used.

Special brass: The multi-component alloy formed by adding other alloy elements to ordinary brass is called brass. The elements that are often added are lead, tin, aluminum, and so on, which can be called lead brass, tin brass, and aluminum brass. The purpose of adding alloying elements. The main purpose is to improve tensile strength and improve processability.

HPb63, HPb62, HPb61, HPb59, H59, H68, H80, H90

Copper

Red copper is pure copper, also known as purple copper. Since its outstanding electrical and thermal conductivity, copper is popularly used in the electrical industry and precision processing industry. The biggest advantage and performance of copper is its good conductivity, which is second only to silver, but the price of copper is much cheaper than silver, and red copper has become the most important part of the electrical industry.

High-purity copper is the primary condition for use in the electrical industry, and purity must be higher than 99.95%. As long as a very small amount of impurities are mixed, the electrical conductivity of the product red copper will decrease greatly, and the oxygen content of copper will also have a great effect on the electrical conductivity. Mainly avoid the following impurities: phosphorus, arsenic, aluminum, lead, antimony, and so on. Such high purity red copper can only be obtained by electrolysis, using raw copper as a positive electrode, pure copper as a negative electrode, and sulfuric acid solution as electrolyte. In the process of electrolysis, the raw copper on the positive electrode is melted and ionized, and pure copper ions will be adsorbed on the negative electrode to get the pure copper we need.

Applications of red copper: wires, cables, brushes, electric spark etching copper, generators, busbars, switchgear, transformers, heat exchangers, pipes, flat plate collectors for solar heating devices, etc.

C11000, C12000, C12000, C26000, C51000

Steel

Steel is an iron-carbon alloy. We usually call it iron steel, and in order to ensure its toughness and Shaping, the carbon element is no more than 1.7%. In addition to iron and carbon, the other elements of steel include silicon, manganese, sulfur, phosphorus, and so on. The other ingredients are to make a difference in the properties of the steel.

Both steel and iron are iron-based iron-carbon alloys, but due to different carbon content, the state and structure of iron-carbon alloys are also different at different temperatures. Iron has poor formability, not easy to deform, and poor weldability. these properties of steel are very good, especially when a certain amount of alloy elements are added to the steel, it will have some special properties, such as high strength, wear resistance, heat resistance, and good corrosion resistance.

After refining and adding other alloy elements, ordinary steel can produce widely used steels with different properties, such as fatigue resistance, heat resistance, impact resistance, wear resistance, corrosion resistance, high polishing, and so on. These excellent steels are widely used in machinery parts, injection mold steel, stamping die steel, aerospace, tools, automobile, home appliances, and other industries.

In order to improve the properties of steel, we usually use heat treatment, stress treatment, quenching and tempering treatment, surface coating, and so on.

SS303, SS304, SS316, SS416, mild steel, Carbon steel, 4140, 4340, Q235, Q345B, 20#, 45#

Plastic

Plastics are polymers, and their main components are synthetic resins. In addition, according to the need to add some specific uses of additives, such as plasticizers that can improve plasticity, anti-aging agents to prevent the aging of plastics, and so on.

Although the relative molecular weight of the polymer is very large, its composition is not complex and its structure has certain rules. They are made by polymerization of small molecules, such as polyethylene plastics, which are polymerized by ethylene molecules. When polyethylene plastic is heated to a certain temperature range, it begins to soften until it melts into a flowing liquid. Melted polyethylene plastic will become solid again after cooling and then melt into liquid after heating. This phenomenon is called thermoplasticity. Polyethylene, polyvinyl chloride, and polypropylene are all thermoplastics. And some plastics can only be softened when heated in the manufacturing process and can be molded into a certain shape, after processing will no longer be melted by heat, with thermosetting properties, such as phenolic resin.

Plastic is a poor conductor of heat, which has the function of noise elimination and shock absorption. Hardness, tensile strength, elongation, and impact strength of plastics. Because of its small specific gravity and high strength, the plastic has a higher specific strength.

Plastic parts are widely used in every field of life, such as household appliances, instruments, wires and cables, construction equipment, communications electronics, automotive industry, aerospace, daily hardware, and so on.

ABS, PC, PE, POM, Delrin, Nylon, Teflon, PP, PEI, Peek, Carbon Fiber.

Titanium

Titanium alloys usually used by us consist of titanium aluminum tin vanadium and niobium and different elements are formed in different properties.

The main excellent features of titanium are described below:

Density is small and specific strength is high: titanium density is higher than aluminum but lower than steel copper-nickel but strength lies at the top of the metal.

Corrosion resistance and heat resistance are good. New titanium alloys can be used for long term at temperatures of 600 ℃ or higher.

Low-temperature resistance performance: titanium alloy Ti-Al _ (2), Ti _ (2-O) and Ti alloys represent low-temperature titanium alloys whose strength increases with decreasing temperature, but plastic changes are little. Maintaining good ductility and toughness at-196-253 ℃ low temperature avoids metal cold brittleness and is the ideal material for cryogenic vessel storage tank etc.

Tensile strength is close to its yield strength: titanium shows a high yield strength ratio (tensile strength/yield strength) indicating poor plastic deformation during the forming of titanium material. Because titanium yield limit and elastic modulus ratio are large, titanium forming can be greatly resilient.

Heat transfer performance is better: although thermal conductivity of titanium is lower than carbon steel and copper because titanium has excellent corrosion resistance, the thickness can be greatly thinned, and a heat resistance of surface and steam decrease thermal resistance, too surface without scaling can reduce thermal resistance, so that titanium heat transfer performance increases remarkably.

Based on the above excellent performances titanium alloys are mainly applied in the aerospace aviation industry marine biomedical field automotive industry etc.

Titanium Grade 1, Titanium Grade 2.

Finishing

Machined

The machined surface means the workpiece surface effect, which is directly processed on the workpiece by all kinds of machines and equipment without any post-processing.

With the increasing precision of modern machines, the surface quality of workpieces is getting better and better. Although the machining lines can be seen on the workpiece surface, it is actually very smooth, and the general machined surface quality can reach at Ra3.2.

Polishing

Polishing is a process of grinding and modifying the surface of parts using a variety of tools and media. The function of polishing is to make the surface of the part more smooth and glossy, however, it can not improve the geometric shape and dimensional accuracy of the part.

Technically, polishing refers to the use of abrasives and machinery to smooth the surface of the part, and the use of machinery to apply abrasives to a loose part surface is a more positive process, which will lead to a smoother, brighter surface finish.

The polishing used on mechanical parts is generally divided into three steps:

The first step: The surface is generally rough after the process of car, mill, NC, spark machine, wire cutting, and other processes, so it needs to be polished with an oilstone.

The second step: After the oilstone operation is the sandpaper work, and we should pay attention to the parts of the round edge, sharp corner position, fillet, and orange peel production.

The third step: It mainly uses diamond grinding paste, and requires a clean polishing room for satisfying the precision requirements in the Ra0.2 polishing process.

Anodizing

Anodizing is divided into common anodizing and hard anodizing.

Metal anodizing is the process of forming a conversion film with wear resistance, corrosion resistance, and other functional or decorative properties on the metal surface by electrochemical treatment in the electrolytic solution, with the treated parts as the positive pole and the corrosion-resistant material as the negative pole.

The objects of anodizing treatment can be aluminum, aluminum alloy, magnesium alloy, titanium and titanium alloy, etc. The anodizing of aluminum and aluminum alloy is widely used and fast developed in the market.

The main function of anodizing is to improve the hardness, wear resistance, corrosion resistance, and surface coloring of the workpiece, which plays an important role in protecting and beautifying the workpiece surface.

Sandblasting is a post-treatment process that uses high-pressure air as the power to spray abrasives into the work which requires surface treatment at a high speed, so that the workpiece surface could be changed. Because of the impact and cutting effect of abrasives on the workpiece surface, the working surface will get different roughness, improve the mechanical properties of the working surface, and improve the fatigue durability of the work. Because of the impact of abrasives, very small micropores are produced on the working surface, thus it is helpful for increasing the adhesion between the work as well as the coating, and prolonging the using life of the coating.

The main functions of the sandblasting are as follows:

To remove oil and rust, sandblasting can remove dirt such as rust skin on the workpiece surface, and form a certain rough surface on the workpiece surface, so that it helps to improve the adhesion of plastic powder and paint film.

For the machined workpiece, the burr on the surface can be removed by sandblasting to make the workpiece more beautiful.

For castings or heat-treated parts, sandblasting can remove the oil and oxide scale on the surface, improve the surface finish, and make the workpiece more beautiful.

Powder coated

Electrostatic spraying of powder coating uses static electricity to adsorb the powder coating on the working surface, and the powder is baked at high temperatures to form a solid coating on the working surface.

Electrostatic powder spraying must first have an electrostatic generator to produce DC high voltage, as well as a spray gun, a power supply system, and a powder recovery system to spray and atomize the powder. The sprayed workpiece should be grounded to a positive pole, and the negative high voltage generated in the discharge needle gun connected to the powder outlet of the spray gun will produce corona discharge through the discharge needle.

At this time, the negatively charged powder particles arrive at the workpiece surface under the action of static electricity and compressed airflow. Since the electrostatic force attraction, the powder is uniformly adsorbed on the workpiece surface for time without falling off, and the workpiece enters the curing furnace to flow flat and solidify, control the humidity or time, and finally form a tight, uniform, smooth and dense coating that binds firmly to the workpiece.

Powder spraying makes the surface of the product smooth and smooth and has a coating with strong acid resistance, alkali resistance, crashworthiness, and wear resistance. the product can withstand strong ultraviolet radiation and acid rain for a long time without coating pulverization, discoloration, shedding, and so on.

Black Oxide

Black oxide is an oxidation treatment for steel surfaces, and is mainly suitable for carbon steel and low alloy steels.

Black oxide heats workpiece (heating temperature ca. 550℃) in dense alkali and oxidizer, so that a dense oxide film (Fe _ 3-Fe _ 3) was formed on the surface of the steel. The iron oxide membrane can isolate air prevents oxidation of steel inside and achieve corrosion resistance purpose.

Steel parts are oxidized to produce protective oxide films mainly composed of magnetic oxide iron oxide (Fe-Fe _ O _ 3) whose color is generally black or blue-black, while cast steel and silicon steel are brown or brown. Oxidation treatment methods include alkali oxidation method, acid oxidation method, etc. It is often used in machinery precision instruments weapons and daily necessities protection and decoration.

Whether iron oxide can be oxidized with dense smooth ferric oxide iron oxide is crucial to select strong oxidants. Strong oxidizer consists of sodium hydroxide, sodium nitrite and phosphoric acid sodium hydroxide. When the color is blue, use their molten solution to handle steel parts; and the color is black when treated with aqueous solutions to handle steel parts.

Brushed

Wire drawing is a kind of surface treatment method which forms lines on the workpiece surface by polishing products and plays a decorative effect.

The wire drawing process is used to make decorative surfaces with wire drawing material for metal stainless steel aluminum surface, and the surface brushed process is also a type of surface-treatment method. It can make the surface clearly display each tiny silk mark, thereby makes a metal matte finish fine-brushed luster product.

Because wire drawing surface treatment can make material surface display different texture, make products more beautiful, wire drawing processing is more and more popular.

There is no unified classification and title for wire drawing processing. Usually, surface effects are divided into straight silk and wild silk. Straight silk is also called silk thread; wild silk is also named snow pattern.

Electroplating

Electroplating is using galvanolysis to plating other types of metals on the workpieces. It uses electrolysis to attach parts surface to the metal film, in order to prevent metal oxidation (corrosion) improving abrasion resistance, conductivity, reflective resistance, corrosion resistance (copper sulfate, etc.), and beauty, etc.

Electroplating metal or other insoluble materials anode, plating workpiece cathode, coating metal cations are reduced to form coating surfaces on the workpiece surface. In order to eliminate interference from other cations, and make plating uniformity and firm, an electroplating solution should be used as a plating solution containing plating metal cations to keep the concentration of metal cations unchanged.

Application

Aerospace
Automotive
Medical
Consumer Products
Zeeltronic
Industrial
Energy
Furniture

Prototyping Case study

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Kemal Your Professional Rapid Prototyping Manufacturer

Kemal is a rapid prototyping manufacturer specializing in prototype services, small volume production, rapid tooling, and 3D printing services. We provide excellent quality, fast turnover, and cost-effective prototype services to customers all over the world.

Kemal has advanced manufacturing technology, cutting-edge production equipment, and a team of engineers with more than 25 years of experience so that you can test the market with high-quality prototype products before production.

Kemal provides prototyping services, including 3D printing, CNC processing, vacuum casting, prototype injection molding, SLS prototyping, etc. If you need a professional prototyping service, Kemal will meet your prototyping needs.

If you have completed the prototype and are ready to move on to the next step, please check out our injection mold manufacturing and injection molding mass production services.

FAQs

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RAPID PROTOTYPING: THE ULTIMATE FAQ GUIDE

Rapid prototyping can directly accept product design (CAD) data without preparing any molds, tools as well as tooling fixtures, and fast manufacture new product samples, molds, or models. Kemal has specialized in rapid prototyping since 1995. And we have a professional team of rapid prototyping with over 10 years’ experience.
Here you can find a guide about rapid prototyping. If you have any other questions, please do not hesitate to contact us.

  • What is Rapid Prototyping?
  • What is the advantage of Rapid Prototyping?
  • What are the features of Rapid Prototyping?
  • How many types of Rapid Prototyping?
  • What is FDM technology of Rapid Prototyping?
  • What is SLS technology of Rapid Prototyping?
  • What is SLA technology of Rapid Prototyping?
  • What is the difference between SLS and SLA technology of Rapid Prototyping?
  • What is the basic principle of Rapid Prototyping?
  • What are the advantages of SLA technology of Rapid Prototyping?
  • What are the advantages of SLS technology of Rapid Prototyping?
  • What is the process for Rapid Prototyping?
  • What are the disadvantages of SLA for Rapid Prototyping?
  • What are the disadvantages of SLS for Rapid Prototyping?
  • How can we use Rapid Prototyping?
  • What is Rapid Prototyping Tooling?
  • What are the differences between 3D Printing and Rapid Prototyping?
  • Compared to tooling manufacturing, what are the advantages of Rapid Prototyping?
  • What is the significance of Rapid Prototyping?
  • What can we do to improve the Rapid Prototyping technology?

 

Q1. What is Rapid Prototyping?

Rapid prototyping (RP), or Rapid prototyping manufacturing (RPM) technology, refers to the general term for the rapid manufacturing of 3D physical entities of arbitrarily complex shapes directly driven by CAD models. This is an advanced manufacturing technology developed in the 1990s. It is a key common technology that serves the development of new products for manufacturing enterprises. It is useful for promoting enterprise product innovation, shortening the development cycle of new products, and improving product competitiveness.

Q2. What is the advantage of Rapid Prototyping?

Rapid prototyping can directly accept product design (CAD) data without preparing any molds, tools as well as tooling fixtures, and fast manufacture new product samples, molds, or models. Hence, the popularization and application of RP technology can greatly shorten the development cycle of new products, reduce development costs, and improve development quality. From the traditional “removal method” to today’s “growth method”, from mold manufacturing to moldless manufacturing, this is the revolutionary significance of RP technology for manufacturing.

Q3. What are the features of Rapid Prototyping?

Rapid prototyping technology discretizes the complex three-dimensional processing of an entity into a series of layered processing, so it greatly reduces the processing difficulty and has the following features:
1.The rapidity of the whole forming process is workable for the modern and fierce product market.

2.It can produce three-dimensional entities into any complex shapes.

3.It is directly driven by CAD model so as to reach a high integration of design and manufacturing. Its intuitiveness and simplicity for modification provide an excellent design environment for perfect product design.

4.During the molding process, special fixtures, molds, and tools are not needed, which saves costs, as well as shortens the production cycle.

5.The high integration of technology is not only the inevitable product of the development of modern science and technology, but also their comprehensive application, with distinctive high-tech characteristics.

The above features lead to the fact that rapid prototyping technology is major suitable for new product development, mold and model design and manufacturing, complex-shaped parts manufacturing, rapid single-part, and small-batch parts manufacturing, as well as shape design inspection, difficult-to-process materials manufacturing, assembly inspection and rapid reverse engineering.

Q4. How many types of Rapid Prototyping?

3D printing technology is a collective name for a series of rapid prototyping technologies. The basic principles of 3D printing technology are all laminated manufacturing. The rapid prototyping machine scans the cross-sectional shape of the product in the XY plane and intermittently shifts the thickness of the layer in the Z coordinate. Finally, a three-dimensional part is formed. Currently, the rapid prototyping technology is divided into 4 types, they are Fused Deposition Modeling (FDM), 3DP technology, selective laser sintering (SLS), Stereolithography Appearance (SLA), and Laminated Object Manufacturing (LOM).

Q5. What is the FDM technology of Rapid Prototyping?

FDM technology is to heat and melt filamentous hot-melt materials. At the same time, under the control of the computer, the three-dimensional spray head selectively coats the material on the worktable based on the cross-sectional profile information and forms a layer of cross-section after rapid cooling. After one layer completes the formation, the machine table is lowered by one height (that is, the layer thickness) and the next layer is formed until the entire solid shape is finished. There are various types of molding materials, and the strength and precision of molding parts are quite high. This technology is mainly applied to small plastic parts.

Q6. What is SLS technology of Rapid Prototyping?

SLS technology is to first spread a layer of metal powder or non-metal powder material on the worktable, and when under computer control, let the laser sinter the solid part of the powder according to the interface profile information, and finally continue to repeat the previous process, form the layer one by one. This method has a simple manufacturing process, fast forming speed, low cost, a wide range of material selection, and is mainly used in the casting industry to produce rapid molds directly.

Q7. What is SLA technology of Rapid Prototyping?

Photosensitive resin as its raw material, SLA technology scans the surface of the liquid photosensitive resin point by point based on the layered cross-sectional information of the part by computer-controlled laser. The thin layer of resin in the scanned area is photopolymerized and cured to form the part of a thin layer. After finishing the curing of one layer, the worktable is moved down a distance of the thickness of the layer, and then apply a new layer of liquid resin on the surface of the cured resin until obtaining a three-dimensional solid model. The method has quick forming speed, high dimensional accuracy, and a high degree of automation that can form any complex shape and is mainly used for the rapid forming of complex and high-precision parts.

Q8. What is the difference between SLS and SLA technology of Rapid Prototyping?

There are 7 distinguished differences between SLS and SLA technology of Rapid Prototyping. You can find more details as follows:
1)Process principle
The process principle for SLS is to generate the high temperature by the laser to raise the temperature of the powder to the melting point for sintering, while for SLA is to generate ultraviolet light by the laser and irradiated on the surface of the material for curing.

2)Resolution rate
Both technologies use laser beams to cure building materials, but they use completely different wavelengths: ultraviolet light for SLA, while infrared light for SLS. Correspondingly, the intensively irradiated area is also different, the ultraviolet light area is much smaller than the infrared light area. Therefore, generally speaking, the resolution of SLA is higher than that of SLS.

3)Mechanical behavior
SLS printers can use many materials in powder form, and the most common one is nylon (PA12), its properties (like color, strength, elasticity, hardness, etc.) can be changed with additives. This material has excellent performance: sturdy, durable, as well as anti-wear.
As for SLA printers, manufacturers usually use their own resin materials, and many third-party options can be chosen, relatively the price is cheaper. Generally speaking, resin materials are harder than nylon, so it is weaker.
Another important difference is their performance under load: the hard resin will become fragments under severe impact, while nylon has a certain degree of elasticity and can be restored to its original state.

4)Visible surface
Solid material with pores will be formed on the visible surface of the product printed by SLS because the air in the powder forms very small bubbles on the sintered material, which will feel a bit rough when touching. And the surface of SLA printed objects will be much smoother.
Besides, nylon powder usually has three colors: black, white as well as gray, while the resin material can generate any colors through white or transparent resin and pigments.

5)Supporting structure
SLA printing technology requires a supporting structure. The printed parts need to be manually cleaned when using a supporting structure, which will take some time. In addition, please note that the supporting materials should be the same as the raw materials used in SLA printing technology. On the contrary, SLS printing technology is one of the few examples that does not require any supporting structure, because the unsintered powder acts as a supporting structure during the printing process.

6)Post-processing
Although the printed products of them can be post-processed, there are still some differences. And we should check with the professional supplier before doing post-processing. For example, polishing is not needed for SLA printing parts.

7)Cost
Nylon is a common material, and the single output of SLS technology is quite large, so SLS technology is usually cheaper than SLA technology.

Q9. What is the basic principle of Rapid Prototyping?

The basic principle of rapid prototyping technology is: split the three-dimensional data model in the computer so as to get the profile data of each layer. Based on this information, the computer controls the laser (or nozzle) to selectively sinter the powder material (or curing layer after layer of liquid photosensitive resin, or cutting layer after layer of sheet material, or spraying layer after layer of hot melt material or adhesive) layer by layer. The sheet-like entities are then piled up layer by layer by means of fusion, polymerization, bonding, etc., and finally the designed new product sample, model, or mold is manufactured.

Q10. What are the advantages of SLA technology of Rapid Prototyping?

1. As the earliest rapid prototyping manufacturing technology, it has been highly developed.
2.Has fast processing speed the short production cycle.
3.It can process prototypes and molds that have complex structure or difficulty informing.
4.Visualize the CAD digital model and reduce the repair cost.
5.Provide samples for tests, which can verify and check the results of computer simulation calculations.
6.It can be operated online and remotely controlled, which is beneficial for production automation.

Q11. What are the advantages of SLS technology of Rapid Prototyping?

The most outstanding advantage of SLS is that a wide range of materials can be used for it. Theoretically, any powder material that can form interatomic bonds after heating can be used for SLS, including paraffin, polymer, metal, ceramic powder, and their composite powder materials. Because of the wide variety of SLS molding materials, the wide distribution of molding properties, material savings, suitability for multiple purposes, and no need to design and manufacture complex support structures, SLS has been more and more popular and widely used nowadays.

Q12. What is the process for Rapid Prototyping?

The rapid prototyping process includes: pre-processing (the construction of the three-dimensional model, the approximate processing of the three-dimensional model, as well as the slicing of the three-dimensional model), layered overlay molding (the manufacturing of the cross-sectional profile and the overlap of the cross-sectional profile) and post-processing (like surface treatment, etc.) ).

Q13. What are the disadvantages of SLA for Rapid Prototyping?

1.The cost of the SLA system is a bit high, and the cost of use and maintenance is quite expensive.

2.SLA system is such precision equipment that needs to operate on liquids that it requires a rigorous working environment.

3.Most of the material for molded parts are resin, so they have limited strength, rigidity, and heat resistance, which is not suitable for long-term storage.

4.The preprocessing software and the driving software need a large amount of calculation and have a close relationship with the processing effect.

5.The software system is complicated to operate and difficult to learn. Besides, it uses a file format that is not familiar to the majority of designers.

Q14. What are the disadvantages of SLS for Rapid Prototyping?

1.Shrinkage of printed products
After sintering, nylon and other powder materials shrink. Shrinkage is affected by various factors, including the powder type, the laser energy used for particles sinter, the part shape, and the cooling process. Please be aware that the part does not shrink symmetrically in all directions.

2.The actions after printing are more complicated.
After the printing process, there is enough time to cool the powder, so we can remove the material block. Workers need to dig out parts from the material block, use a vacuum cleaner to remove excess powder or use the wind to sweep away the remaining particles. As soon as completing all the work, the sintered print can be cured by heating to increase strength. In addition, sometimes it may take time to dye, frost, or paint the surface.

3.Color change / moisture absorption
If the printing part is to be dyed, painted, or coated, its porous structure may absorb a large amount of dust, oil, or water from the air, which leads to the color change or losing some weight.

4.Processing and material loss

Q15. How can we use Rapid Prototyping?

Rapid Prototyping can be used for design evaluation and function tests in the product research and development stage. Moreover, it can also be used for the industries of household appliances, automobiles, toys, light industrial products, architectural models, medical equipment and artificial organ models, spacecraft, military equipment, archaeology, industrial manufacturing, sculpture and film production, and so on.

Q16. What is Rapid Prototyping Tooling?

Rapid Prototyping Tooling is a tool that uses its specific shape to form products with a certain size, shape, and surface precise. It is a major used in mass production. Even though the production and mold manufacturing costs are quite high, the fee for each product is greatly reduced due to mass production.

Q17. What are the differences between 3D Printing and Rapid Prototyping?

Rapid prototyping is a new type of technology based on the material accumulation method. It is considered a major achievement in the manufacturing field in the past 20 years. By integrating mechanical engineering, CAD, reverse engineering technology, layered manufacturing technology, numerical control technology, material science, and laser technology, it can directly, accurately, automatically, and quickly transform design ideas into prototypes with certain functions or directly manufactured parts. This provides a high-efficiency and low-cost method for realizing part prototyping and verification of new design ideas.
3D printing technology refers to the latest rapid prototyping devices using light-curing and paper lamination technologies. It is basically the same as normal printing. The printer contains liquid or powder and other “printing materials”. After connecting to the computer, the “printing materials” are superimposed layer by layer via computer control, and finally, the design in the computer is turned into a real object.

Q18. Compared to tooling manufacturing, what are the advantages of Rapid Prototyping?

Rapid prototyping technology is not limited by product structure and shape. As long as there is CAD data, it can be easily completed no matter how complex the product shape and structure are. Therefore, this technology is very suitable for OEM & ODM projects. Moreover, the use of rapid prototyping technology does not need to open a new mold, which can reduce the cost of developing new products and shorten the cycle. In addition, most of the rapid prototyping equipment can be operated 24/7 and without an operator, which is beneficial for saving labor costs and improving production efficiency.
Rapid prototyping technology can also be used for product design, development, testing, small batch production, etc., and any project that requires physical proofing or testing can use rapid prototyping technology.
Furthermore, the amount of post-assisted processing of rapid prototyping technology is greatly reduced, so as to avoid data leakage and the time span of outsourced processing.

Q19. What is the significance of Rapid Prototyping?

First of all, rapid prototyping greatly shortens the research and development time for new products.

Secondly, it improves the possibility of manufacturing complex parts.

Thirdly, it plays an important role in improving the first-time success rate of new product production. Because we can find out the design problems in time and then make an improvement to avoid large losses.

Fourthly, we can carry out a new product design, sample manufacturing, market promotion, and production preparation at the same time.

Lastly, it helps to save lots of mold opening costs.

Q20. What can we do to improve the Rapid Prototyping technology?

Rapid prototype technology is commonly used in the manufacturing industry (up to 67%), which shows that it has an important effect on improving the design and manufacturing level of products.
There are still some shortcomings in rapid prototyping technology. In the future, we can improve rapid prototyping technology on the following aspects:
1.Improving the reliability, productivity, and production capacity of the rapid prototyping system, especially the production accuracy;
2.Developing economical rapid prototyping system;
3.Improving and innovating rapid prototyping methods as well as processes;
4.Application of rapid mold manufacturing;
5.Developing rapid prototyping materials with good performance;
6.Developing high-performance software for rapid prototyping.