Prototyping is the
art of making samples and models to test a product before release. It usually
involves schematics, design, coding if needed, and working. It is usually done
to test a product and analyze it with a critic’s eye and then to make further
changes as needed to provide people with the best product.
Rapid
Prototyping is a process of extremely quick fabrication i.e.
putting up the physical structure of a model. It usually uses Computer-Aided
Design i.e. CAD and further done by the addition of parts or 3D printing. The
structure produced by it can either be too close to the real product or be too
different from that of the product to be made.
Working
There are a lot
many things involved in rapid prototypes. They are not just the creation of CAD
or 3D printers. It involves several layers and processes, including casting,
moulding, shaping, matching, etc. It involves 2 main techniques:
- Subtracting: A big block of material is carved
in by various tools to reach the desired shape or output.
- Compression: Shapes are made using different moulds and then are compressed together to join and form a particular shape.
Types
Rapid prototyping is
not an easy task but to ease its working, it has several types, and the best
suitable can be used by the assembler or the person making the prototype. The
processes include:
- Vat Photo polymerization: This technique is
considered to be a very fast and pocket-friendly method of 3D printing.
The photosensitive liquid layer solidifies as the UV light passes through
it.
- Selective Layer sintering: Used for metals and
plastic; it involves a sintering powder that builds a bed layer one at a
time. It usually gives a rough end product than a smooth one.
- Material Jetting: It involves a thermoplastic
filament that is melted inside the printing space as per the design shown
on the computer. It is highly inexpensive and easy to use.
- Powder bed fusion: Done by melting fine metal
powder into a bed layer by layer by using an electron beam or a laser. It
is used to make highly complex parts of an automobile, military, etc.
- Sheet Lamination: This is done by using a series of laminated sheets, usually one over another that is cut by using a laser as per the designs of CAD. The sheets are bonded until the cutting is over.
Application
Rapid Prototyping comes with a lot of aids to humans. It helps in
easy understanding of the image in the 3D view. It aids imagination,
development, fault detection, and correction in developing and manufacturing
new products especially mass production. It is a way that has not just helped
automobiles but is now moving towards other industries like medical for
injection moulds, ultrasound sensors, etc. and aerospace for the various parts
of the jets and airplanes. It has now become a popular method that is not only
embraced by people but has shown significant popularity in the world of
manufacturing.
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