THINK OUTSIDE THE BOX WITH RAPID PROTOTYPING

When someone thinks of 3 Dimensional Printing, Rapid Prototyping or Additive Manufacturing (so named because generally material is “added” together to create objects) they think of the process that just creates the part.   This usually first involves the creation of what we call a “virtual prototype” or computer model of the idea we are interested in creating.  Once the virtual prototype is created, we utilize software to send the virtual prototype to the 3 Dimensional Printer and “Print” the actual prototype. The process of creating the prototype is incredibly valuable in itself.  The part can be handled, it can be assembled to other parts and the prototype can be evaluated and tested.  This can all be done in a matter of hours. It is important to note, however, that there are many secondary uses of 3 Dimensional Printing when it comes to creating prototypes.  Some examples: You have a sheet metal part you wish to prototype that requires some special bend die tooling to be created.  Instead of investing in permanent type tooling, you could create a virtual prototype of the tool based on the virtual prototype of the part.  Rapid Prototype the tool and you have a temporary tool to use to finish forming the sheet metal part.  A holding fixture is needed to use to hold two parts together so you can glue them together.  Create a virtual prototype of the fixture based on the virtual prototype of the two parts and rapid prototype the fixture.   A silicone prototype needs to be created.  Create a virtual prototype of the desired part.  Use this part to create a virtual mold for the silicone part.  Rapid prototype the mold and now you have a mold to cast the actual silicone part. An assembly that utilizes a spring requires a tool that keeps the spring compressed until the assembly is completed.  Using the virtual prototype of the assembly, create a virtual prototype of the spring retention tool.  Rapid prototype it and use it to assemble the parts with the spring.  As you can see the possibilities are endless when you start thinking out of the box in terms of what Additive Manufacturing can do.  So start thinking a little of the box and start increasing your productivity and reducing your design cycle times! Mark A. Jackson P.E. President Blue Dolphin Design and Engineering, Inc. www.bluedolphinengineerng.com