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The Art of Rapid Prototyping and Rapid Tooling

It is often said that a sign of good worker is the tendency to plan before making any more regardless if it involves small or big tasks. This kind of thing becomes even truer in the case of people who deal in manufacturing of materials.

Rapid Prototyping is the term used to denote a set of techniques used in creating a scale model of a part of a machine with the help of CAD data. It makes use of several techniques such as Stereolithography considered to be the first Rapid Prototyping process, Selective Laser Sintering which is considered to be stronger than Stereolithography and can be used on a variety of materials, the relatively cheap Laminated Object Manufacturing although not as common as Stereolithography and Selective Laser Sintering, Fused Deposition Modeling which can be used with standard engineering thermoplastics, Solid Ground Curing that takes away the need for post-cure, and Inkjet printing techniques.

Regardless of which technique is in use, rapid prototyping follows a number of common basic steps, the first of which is to convert a CAD model into an STL format. Once this has been done, and the resolution set, the rapid prototyping machine makes sliced layers of the model. Afterwards, the first layer of the model is created and is lowered by the thickness of the succeeding layers. One this has been done, the model and the supports are removed and the surface is given some finishing touches.

This procedural model of how rapid prototyping work is actually the same mode being used in rapid tooling. In rapid tooling, the RP model is used either in quickly creating mold or as a way to fabricate the tool in a short span of time. RT can come in the form of Silicone Rubber Molding, Composite Molding and Direct AIM, among others.

In Silicone Rubber Molding technique, the mold fabrication time usually lasts for 15 days. If you want to go faster than that, you might opt to go for the RTV silicone rubber molding process. This is the last expensive rapid tooling technique and could give you about a dozen prototype parts in one mold. On the other hand, composite molding takes about 6 weeks but could produce up to 500 parts in one mold. They are usually cheaper and have a lower lead time than aluminum tools. Lastly, Direct AIM takes about two week for the fabrication process to finish, producing about 10 parts each day for each of the cavity.

Today’s market offers a variety of technologies to enable the rapid prototyping rapid tooling included, of parts. The differences in these technologies lie in the way layers are made in order to create the parts.

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