What is Rapid Prototyping?

Rapid prototyping, or RP, is a quick technique that’s used to create a working model of a physical part, component, or assembly. Usually, teams prefer this method to fix problems and save money before mass production. So, machinists work closely with designers and engineers to assemble an accurate representation based on a 3D computer-aided design (CAD). And most of the time, that’s done using additive manufacturing, which is commonly known as 3D printing.

How Does RP Work?

RP harnesses the power of selective laser melting to create a finished product that most closely matches the initial design. Thus, it’s said to render a high fidelity model, as opposed to a low fidelity model wherein there’s a distinct difference in procedure and outcome. That’s because rapid prototyping services use a wide variety of manufacturing methods to get the job done as accurately and efficiently as possible, including multi-axis machining, molding, die casting, and extruding.

Different Rapid Prototyping Techniques

Although additive manufacturing is one of the most common RP methods in modern machining and customized orders, two more conventional techniques are still in use today. Those methods are:

Compressive – Experts take liquid or semi-solid material and mold it into a designated form while it is solidified using compressive sintering, molding, or casting.

Subtractive- Machinists carve a block of raw material to create the desired shape through CNC turning, milling, or grinding.
Pioneer Cuts offers a range of prototyping support to staff and clients, with rapid prototyping consultancy services and RP technology assistance as well.

What Are the 6 Types of Rapid Prototyping?

It’s important to understand material properties before settling on a rapid prototyping technique, and it’s crucial to review the different types of RP ahead of time. As such, these are your primary choices:

#1. Selective Laser Sintering (SLS)
It’s used for plastic and metal prototyping projects, with a powder bed to create the model one precision layer at a time. Using a focused laser to heat and sinter the material, the finished product is usually rougher and may require a secondary finish.

#2. Selective Laser Melting (SLM)
Sometimes called “powder bed fusion,” this process renders high-strength models of intricate parts. Thus, it’s one of the most favored techniques for aerospace, automotive, medical, and defense industries that require titanium, steel, and aluminum machining.

#3. Fused Deposition Modelling (FDM)
Also known as material jetting, this technique is simple and inexpensive. It uses a spool of thermoplastic filament to create a 3D printed model through layered CAD control. And while early applications were of poor quality, new FDM methods are standard for product development.

#4. Stereolithography/Vat Photopolymerization (SLA)
This quick, cost-effective method was the first successful technique to use 3D printing. The substance solidifies layer-by-layer with a photosensitive liquid bath and computer-controlled ultra-violet (UV) rays until the desired result is achieved.

#5. Laminated Object Manufacturing (LOM)
Far less sophisticated than SLS or SLM, laminated object manufacturing is possible in nearly all conditions. LOM creates thin laminates after the material is cut with lasers or specialized tools. A CAD pattern design erupts and each layer gets bonded until the prototype is complete.

#6. Digital Light Processing (DLP)
Digital Light Processing, or DLP, uses the polymerization of resins after they’ve been cured with a more conventional light source than vat photopolymerization (SLA). This technique usually requires support structures and curing but it’s still faster and cheaper than some other methods.

Pioneer Cuts understands how important accurate and timely prototypes can be, so our machinists strive to suggest the most efficient and cost-effective methods regardless of the project’s scope or scale.