Rapid Prototyping (RP)
Rapid prototyping (RP) is a set of techniques used to quickly manufacture physical 3-dimensional parts from computer-aided design (CAD) models. This technology first came about in the late 1980s and has since grown exponentially in its potential applications. The main advantages of RP techniques are the short lead time for production, the ability to produce complex shapes and a variety of materials. These techniques are also relatively inexpensive compared to subtractive and traditional additive manufacturing techniques.
There are a variety of different rapid prototyping techniques, each of which use different types of materials and manufacturing methods. Some of the most popular RP methods include stereolithography, selective laser sintering, fused deposition modelling, and three-dimensional printing.
Stereolithography (SLA) is one of the oldest rapid prototyping techniques, using lasers to cure a layer of UV sensitive liquid plastic. The top layer is then peeled off and a new layer is added, repeating the process until the desired product is achieved. SLA is often used to create prototype parts, but can also be used to create models, end-use parts, or patterns for investment casting.
Selective laser sintering (SLS) is very similar to SLA, except that the laser is used to fuse powdered material together forming a single solid part. The powder used for sintering must be made of a material that can withstand being melted by the laser, such as nylon or glass. SLS is often used to create prototype parts for applications where surface finish is not important or for end-use parts where strength or temperature resistance is desired.
Fused deposition modelling (FDM) is a process that works by extruding a thermoplastic filament in a very precise pattern. The thermoplastic filaments are melted and deposited to build up the part layer by layer. FDM is often used for producing parts that are strong and dimensionally accurate, and can be used for prototypes or end-use applications.
Three-dimensional printing (3DP) is a process where an object is created by laying down successive layers of material, such as metal alloys, plastics, and resins. The layers are “printed” or built up one by one from the bottom to the top of the desired object. 3DP is often used to produce models, prototypes, and end-use parts with complex geometries, no matter how intricate.
RP techniques are now being used in industries all over the world, from automotive and aerospace manufacturing to medical, consumer goods, and even architecture and construction. These techniques have not only revolutionized the way we design and manufacture products, but they have also opened up new opportunities for rapid prototyping companies and their customers.
