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Rapid Prototyping (RP) is currently the most advanced method for quickly creating a prototype. This is achieved by using a Rapid Prototyping machine. Rapid Prototyping machines can produce prototypes in a very short time. Depending on the complexity of the prototype, it may take anywhere from a matter of hours to a few days for its completion. Rapid prototyping is also commonly called solid free-form fabrication, layered manufacturing, or computer automated manufacturing.

Rapid Prototyping helps in the following areas:

• Help to visualize models better and thereby increase communication
• Help you to test and verify your design for fit & function
• Decrease development time and hence time to market
• Help avoid costly manufacturing mistakes

In addition to parts for testing and verifying, Rapid Prototyping can be used for the production of ‘short run’ parts where multiples are produced without traditional tooling and molds being required. This is also known as Rapid Manufacturing.

Rapid Prototyping grows a part using a Computer-Aided Design (CAD) model and a Rapid Prototyping machine to create a physical model using an additive method, layer by layer. A variety of materials are available depending on the specific method of Rapid Prototyping equipment used. These materials can include plastic, resin, metal and wax. Machining processes, such as CNC milling use a subtractive technique, where the material is removed from a solid block to create the part.

Here’s a brief explanation of how Rapid Prototyping works:

Step 1: A computer-aided (CAD) model is constructed and then converted to STL (Standard Tessellation Language which is native to CAD software) file format. The STL file is the standard interface between the CAD software and the Rapid Prototyping machine.

Step 2: The Rapid Prototyping machine reads the STL file and creates cross-section layers of the model.

Step 3: The first layer of the model is created. The next layer is added at the thickness determined by the Rapid Prototyping machine and the process is iterated until the complete model is built.

Step 4: Selected users from the stakeholder groups participate in a brainstorming session to test the prototype.

Step 5: User observations are summarized and evaluated.

Step 6: The prototype is refined where necessary and the above processes are repeated. If necessary.

What is it Used For?

Inventors and product development teams easily use rapid prototypes to help communicate their invention to customers, supervisors, manufacturers without communication barriers that can sometimes occur with 2D drawings and words. Prototypes are now an integral part of the design-to-market process as they help ensure projects run as quickly and cost efficiently as possible.

Rapid Prototypes may also be used for communicating with manufacturers (especially over seas), to attract investors, customers and in consumer marketing focus groups. As you can imagine, it is much easier to communicate an invention or design using a 3-D prototype than with a drawing or blueprint.

What Does it Cost?

Costs vary widely based on the complexity and size of the invention, the type of process used and quantities required. You can gain a quote by contacting companies who offer Rapid Prototyping services or requesting a quote on-line.

Annette Kalbhenn is Business Development Manager at a Rapid Prototyping service bureau. For more info on how you can benefit from Rapid Prototyping check out http://www.3dPrototype.com
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