Evolution of rapid prototyping

Rapid prototyping makes it possible to quickly produce prototypes and models using tooling and materials that have evolved over time to keep pace with changes in industrial demand. With 3D printing, however, it is the technology itself that influences the use of the processes.

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Evolving needs for rapid prototyping

Until the 1980s, companies wanted to control their production costs and ensure product performance. It was necessary to test products without expensive tooling, and in a much shorter time than with conventional techniques. In the 1990s, the concept of quality appeared, which required the use of prototypes to validate the quality criteria of the product. Finally, in the 2000s, it became time to market that was important: companies wanted to be the first to launch a new product on the market, which requires an extremely short design development process. All this influenced the development of machines and technologies for producing prototypes more and more rapidly.

With the crisis, the need to control costs has reduced the number of prototypes for the development of a product. However, requests for certification and the need to contextualize and test the products require the use of prototypes. Thus, while the needs vary, they always continue to exist.

A constantly evolving technology

The first stereolithography machines appeared in 1984. This rapid prototyping technology makes it possible to solidify layers of liquid polymer that are sensitive to ultraviolet radiation, by means of laser technology. In the decades that followed, other rapid prototyping technologies emerged, for example, fused deposition modeling (FDM) and selective laser sintering. The first-ever 3D rapid prototyping system based on FDM technology was introduced in the 1990s. The latest development in rapid prototyping, the 3D printer, was launched in the 2000s.

The 3D printing revolution

While the 3D printer segment is gaining ground on other technologies, this innovation has also led to the popularisation of rapid prototyping in general. Today, more and more industries are seeing the value of using prototypes to validate technical or visual choices. Nevertheless, 3D printing has its limitations, which can make other methods more attractive. Thus, the parts produced with 3D printing are generally of small size and often require post-processing when it is necessary to obtain a visual appearance of quality. As soon as the number of parts required increases, it is often more economical to use vacuum duplication or 3D machining.

This proves that the rapid prototyping industry still has some good days ahead of it!

Rapid Prototyping (RP) enables the quick fabrication of physical models using three-dimensional computer aided design (CAD) data. Used in a wide range of industries, Rapid prototyping allows students to turn innovative ideas into successful end parts rapidly and efficiently.

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Rapid Prototyping techniques offer multiple benefits, such as:

• Fast and effective communication of design ideas
• Effective validation of design fit, form, and function
• Greater design flexibility, with the ability to run quickly through multiple design iterations
• Fewer production design flaws and better end-products!

Rapid Prototyping — A Quick History

Rapid prototyping systems emerged in 1987 with the introduction of stereolithography technology, a process that solidifies layers of ultraviolet light-sensitive liquid polymer using laser technology. In subsequent years, other rapid prototyping technologies were introduced, such as: Fused Deposition Modeling (FDM), Selective Laser Sintering and Laminated Object Manufacturing. The industry’s very first 3D rapid prototyping system based on FDM Technology was introduced in April, 1992, by Stratasys. The first 3D rapid prototyping systems based on PolyJet technology were introduced by Objet in April, 2000.

How does Rapid Prototyping Work?

Rapid Prototyping, also known as 3D printing, is an additive manufacturing technology. The process begins with taking a virtual design from modeling or computer aided design (CAD) software. The 3D printing machine reads the data from the CAD drawing and lays down successive layers of liquid, powder, or sheet material — building up the physical model from a series of cross sections. These layers, which correspond to the virtual cross section from the CAD model, are automatically joined together to create the final shape.

Rapid Prototyping uses a standard data interface, implemented as the STL file format, to translate from the CAD software to the 3D prototyping machine. The STL file approximates the shape of a part or assembly using triangular facets.

Typically, Rapid Prototyping systems can produce 3D models within a few hours. Yet, this can vary widely, depending on the type of machine being used and the size and number of models being produced.

Learn How 3D Printing Works

Stratasys offers two powerful 3D printing technologies:

FDM Technology uses production-grade thermoplastics for durable, usable parts that are thermally, chemically and mechanically tough.

PolyJet Technology jets liquid photopolymer in fine droplets and solidifies it with UV light, resulting in impressively smooth, detailed surfaces and the ability to print clear, flexible and rigid components in one job.

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