Rapid Prototyping

Rapid prototyping assists businesses in turning ideas into genuine proof of concepts, progressing these concepts to high-fidelity prototypes that appear and function like final goods, and guiding items through a succession of validation steps toward mass manufacturing.
Simply said, rapid prototyping could alter the way you conduct business. Designers and engineers can use rapid prototyping to generate samples directly from the CAD data quicker than ever before, as well as make quick and frequent adjustments to their ideas based on practical testing and feedback.

What is rapid prototyping?

Rapid prototyping (RP) uses multiple manufacturing processes to quickly manufacture a real item directly from its CAD model data. Rapid prototyping may be utilised for any component or sub-component at any point of the product development cycle. To get the intended portion, prototyping can be performed several times during the new product design process utilising test data.
Rapid prototyping is a relatively recent word that refers to the process of swiftly building a prototype in order to aesthetically and operationally evaluate a component or certain part attributes. Individual elements are sometimes quickly made independently and combined to test the prototype product.
This is an important component of the development process since it allows organisations to test different concepts while also assessing and updating designs as they go, refining and validating ideas rapidly. When the rapid prototyping approach is used, products can be moved much faster along the sales funnel and presented to stakeholders and investors without reluctance.

Methods in Rapid Prototyping

Rapid prototyping methods are becoming more advanced as new materials, particularly high-performance materials, are developed and used. Rapid prototyping is now almost synonymous with additive manufacturing and 3D printing.

• Fused Deposition Modelling (FDM)

  Fused Deposition Modelling (FDM) is a 3D printing technology in which a thermoplastic filament is melted and extruded by a printer nozzle before being deposited layer by layer in the build area. However, in compared to other plastic 3D printing technologies, it has the lowest precision and accuracy and is not suited for producing complicated patterns or items with intricate details. Chemical or mechanical polishing processes can be employed to create a superior surface finish.

• Stereolithography (SLA)

  Stereolithography (SLA) is a 3D printing method that employs a laser to photopolymerize liquid resin into a rigid plastic. Because of its excellent accuracy, resolution, and material adaptability, it is often used by experts. Among all plastic 3D printing technologies, SLA parts have the highest resolution and accuracy, the most intricate details, and the smoothest surface finish, which makes them ideal for creating high-fidelity prototypes that closely match the final product, as well as functional prototypes that require tight tolerances.

• Selective Laser Sintering (SLS)

  Selective Laser Sintering (SLS) is a widely used additive manufacturing method for industrial applications, with engineers and manufacturers across a wide range of sectors relying on its ability to produce strong and functioning parts. SLS 3D printers employ a high-powered laser to join tiny polymer powder particles. During printing, the unfused powder functions as a support for the component, reducing the need for extra support structures.

• CNC Machining

  CNC (Computer Numerical Control) machining is a quick prototyping technique that uses computer-controlled cutting tools to create prototypes out of solid materials such as plastic, metal, and rubber. It is a quick and easy technique to create precise and detailed prototypes, especially for high-precision items. However, when compared to additive manufacturing equipment, CNC machines can be more difficult to operate and set up, and may require specific tooling, handling, placement, and processing for particular materials and designs, making them more expensive for single prototypes.

Advantages of Rapid Prototyping

• Effectively Communicate Ideas

Creating physical models allows designers to effectively communicate their ideas and designs to colleagues, clients, and collaborators, providing a level of understanding that cannot be achieved through visualization alone. Rapid prototyping is an essential tool in this process, allowing for the creation of physical models quickly and efficiently. This facilitates clear and actionable feedback from users, which is crucial for understanding user needs and refining and improving designs.

• Simplified concept implementation

Rapid prototyping is an effective method for moving from early concepts to practical, low-risk concept explorations. It enables the rapid creation of physical models that closely mimic the final result. This enables designers to go beyond virtual representation and compare alternative concepts side by side, making it easier to comprehend the design’s appearance and feel.

• Focus on saving both money and time

Rapid prototyping enables the early discovery and rectification of design faults in product design and manufacturing. This can save money on redesigns and equipment modifications. Engineers can study prototypes that are identical to final goods, which decreases the possibility of usability and production feasibility concerns appearing before mass production begins.

• Iterative Design and Instantaneous Change Implementation

Before arriving at a finished product, the design process is constantly iterative, needing numerous rounds of testing, review, and improvement. Rapid prototyping, notably 3D printing, is one of the most efficient ways to accomplish this. This technology enables speedier construction of more realistic prototypes, as well as the capacity to make rapid modifications, which improves the entire trial-and-error process.

• Extensive testing and minimising design issues

Identifying and correcting design faults early in the product design and production process might assist save costly modifications and tooling adjustments later on. Engineers can use rapid prototyping to evaluate prototypes that closely resemble final goods, lowering the risk of usability and manufacturability difficulties before starting full-scale production.

Need for Rapid Prototyping

EMI Seals & Gaskets has decades of development and manufacturing expertise in the industrial, military, aerospace, defence, automotive, and hazardous area industries. Technical engineers at EMI Seals and Gaskets have been trained in all of these prototype methods, understanding their strengths and limits, and will select the optimal prototyping method and controls for your unique application.

Please contact us if you want prototypes fast. Fill out the “Prototype Part Request” form and upload a sketch, drawing, or CAD file. One of our technical professionals will contact you the same day or the next. Alternatively, you can call us by telephone. We are ready to help.