10 Tips to Reduce the Costs and Lead Time of Rapid ...

Rapid prototyping helps companies turn ideas into realistic proofs of concept, advances these concepts to high-fidelity prototypes that look and work like final products, and guides products through a series of validation stages toward mass production.

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Engineers and designers have been creating hardware prototypes for decades, but the tools, materials, and methods used to create those prototypes have evolved tremendously. With rapid prototyping tools like 3D printers, product development teams can create prototypes directly from CAD data, and quickly execute rounds of design revisions based on real-world testing and feedback at a substantially lower cost than ever before.

Prototyping with 3D printers, however, can be quite different than with working with other traditional tools or outsourcing to machine shops and service providers. Cost factors, efficiencies, and design rules often don&#;t directly translate.

In this guide, we collected ten insights to help you optimize your 3D printing rapid prototyping workflow to be as cost and time efficient as possible, from choosing a technology to practical design tips.

1. Prototype In-House

For any business involved in prototyping, one of the first questions that comes up is whether to order prototypes from service bureaus and machines shops or to purchase equipment to prototype in-house.

Rapid prototyping stops being rapid when an outsourced part takes multiple days or even weeks to arrive. Outsourcing can quickly become expensive when a project requires dozens or more iterations. On the other hand, purchasing a variety of machinery to produce all the different parts in a single product often requires substantial investment, a dedicated location, and expertise to operate.

The answer is not always clear-cut, but the best practice for most companies is to bring the most frequently used prototyping tools in-house and outsource larger parts, and parts that require non-standard materials or complex machinery.

Smaller desktop or benchtop 3D printers can cover many of the prototyping needs for most companies. They&#;re fast, easy to use, can operate in an office environment, and require minimal training. Depending on the number of parts and printing volume, investment in a desktop 3D printer can break even within months and save weeks or months of lead time over the course of development.

Curious how 3D printing in-house compares to outsourcing or other prototyping or production methods for your application? Use our interactive tool to calculate return on investment and time savings with 3D printing.

2. Choose the Right Technology and Machinery

To find the right prototyping materials and equipment, first, consider what you need from your prototypes. Do you need prototypes for visual demonstration only or for testing the mechanical attributes of your product?

Understanding these needs will help you choose the right technology. For example, for basic concept models the only requirement could simply be speed&#;finish and details may not matter. Looks-like prototypes, however, may require technologies and materials designed for fine details and high-quality surface finishes, while functional prototypes might need to withstand mechanical stress or have specific properties, such as optical transparency.

Desktop 3D printers offer solutions for a wide variety of applications and can produce parts in materials with varied mechanical properties.

Compare the three most established 3D printing technologies for plastics today: fused deposition modeling (FDM), stereolithography (SLA), and selective laser sintering (SLS).

3. Automate Post-Processing

Post-processing is an often overlooked, but potentially time-consuming aspect of prototyping with 3D printing. Some technologies require less post-processing than others, but all 3D printed parts require a certain degree of post-processing.

Some aspects of post-processing can be automated to reduce labor time and costs. One example of an automated system is the Form Wash and Form Cure for Form 2 3D printers that simplify the cleaning and post-curing of stereolithography (SLA) parts.

4. Assemble Large Parts From Multiple Prints

3D printing large parts can be a costly and lengthy process, often requiring outsourcing parts to service providers with large industrial printers.

But, just as assemblies consist of many individual building blocks, splitting a model into smaller parts is a great solution to creating objects larger than what fits into the build volume of a 3D printer. You can add features to your design that will allow the prints to align themselves, or simply split the parts with straight cuts, requiring you to align them during the fastening process.

When selecting a bonding method, your primary consideration should be the strength of the bonded joints, which is dependent on the ultimate use case of the parts:

• Chemical fastening: Use a bonding agent for art, scale models, and complex shapes that are not meant for functional use and to sustain impact.
• Mechanical fastening: Add screw thread or pockets to functional engineering parts that require a robust mechanical connection or if you need to repeatedly attach and detach components.

Add metal threads to 3D printed parts for robust mechanical fastening.

5. Make Parts Hollow

By default, most 3D printers create fully dense parts. When you&#;re not printing functional parts that require a certain strength, hollowing out large and bulky designs can be a great way to save a considerable amount of material and printing time.

Printing time on the Form 2MaterialOriginal Solid15 h 35 min246.28 mLHollow7 h 47 min77.37 mLSavings50%68%

Learn how to use Formlabs print preparation software, PreForm, and Meshmixer&#;s (free) hollowing tool to hollow and prepare your model for printing in three simple steps.

6. Adjust Layer Height

Adjusting the layer height is a great way to reduce printing time. On SLA systems, for example, the difference between parts printed with 50 and 100 micron layers is often barely noticeable, but reduces printing time by 50%.

7. Optimize Schedule

There are a few methods for optimizing your printing schedule to get the highest throughput possible, printing close to 24 hours a day.

Best practices for optimizing schedule include:

• Batch multiple parts into one build.
• Print small, shorter runs during the day and large builds overnight.
• Use multiple printers to distribute the workload and increase same-day throughput.
• Use Dashboard to receive alerts when a print finishes and to manage and watch multiple printers remotely.

8. Reduce or Eliminate Support Structures

A poorly oriented part can result in excessive support structures. Excessive supports use more material, increase printing time, and require more post-processing time. Depending on your design, a part can often be printed with limited or without any support structures. Most print preparation software tools allow you to experiment with different part orientations and check how different setups affect overall print time and material usage before printing.

A manifold prototype printed directly on the build platform with limited support structures for overhanging features.

Some technologies might also be better suited to your designs than others. FDM printers often require excessive support structures for designs with complex shapes, angles, and overhangs. Support structures on SLA printers are easy to break away and support requirements can be reduced through smart software. SLS machines do not need support structures at all, as the powder acts as a support for the parts while printing.

9. Optimize the Design

While 3D printers offer a high degree of design freedom, a bit of time spent on optimizing part geometries goes a long way to ensure efficient printing of high-quality parts. When designing a part for 3D printing, make sure to follow design guidelines for the specific technology or printer.

Common optimizations include:

• Maintaining wall thicknesses at or above minimum specifications.
• Eliminating or supporting angled walls and steep overhangs.
• Adding drain holes for hollow designs.
• Consider using lattice structures to achieve an ideal balance between part strength, material usage, and print speed.

10. Prevent Failures

Failed parts and broken machinery wastes expensive engineering time and can set development cycles back by days or even weeks.

Fortunately, 3D printers have developed tremendously since the first desktop printers entered the market ten years ago and professional 3D printers today are tools that companies can rely on.

As a rule of thumb, you can reduce failures to statistical insignificance by following some simple rules:

• Work with reliable machines and companies that provide training and technical support.
• Keep your machine and workspace clean.
• Take the time to set up your prints properly.
• Print only with reliable, tested materials.
• Check the expiration date of materials before printing.
• Carry out regular service and maintenance as specified by the manufacturer.

Get Started With Prototyping In-House

Add 3D printing to your toolset and create precision prototypes in-house for a fraction of the cost and lead time of traditional tools or outsourced solutions.

See the quality firsthand by requesting a complimentary sample part printed on the Form 2 SLA 3D printer.

Material Matters:The Ultimate Guide to Rapid Prototyping Selections #RapidPrototyping #QuickModeling

Rapid prototyping has transformed the product development landscape, greatly enhancing speed and efficiency. However, one pivotal aspect of this process is the selection of suitable materials. With many options, making the right choice for your project is paramount.

In this article, we&#;ll delve deep into rapid fabrication materials, offering valuable insights to assist you in your quest for innovative solutions.

With competitive price and timely delivery, thingyfy sincerely hope to be your supplier and partner.

Material Characteristics

Understanding the characteristics of materials for fast prototyping is fundamental when selecting. Let&#;s take an in-depth look at these vital attributes:

• Strength: Strength measures a material&#;s capacity to endure stretching or breaking when exposed to tension. This attribute becomes especially critical when crafting load-bearing prototypes or components requiring structural integrity. Materials boasting high tensile strength, like specific metals or engineering-grade plastics, are optimal for such applications.
• Hardness: Material hardness indicates its resistance to deformation or scratching. Depending on your project&#;s requirements, you may require quick prototyping materials with high hardness for wear-resistant prototypes or softer materials for ergonomic assessments. Metals such as steel exhibit high hardness, whereas elastomers like silicone offer flexibility.
• Heat Conductivity: Heat conductivity defines a material&#;s ability to transfer heat efficiently. This characteristic is vital when designing prototypes that manage or dissipate heat effectively. Metals like aluminum and copper excel in applications necessitating high thermal conductivity.
• Thermal Response: Thermal response refers to how a material changes in size with fluctuations in temperature. Considering this property is essential to prevent warping or distortion in your prototypes when exposed to varying temperatures. Certain materials exhibit minimal thermal expansion, while others undergo significant changes.
• Surface Finish: Surface finish relates to the texture or quality of a material&#;s surface. The surface finish of your prototype can significantly impact aesthetics, functionality, and even aerodynamics. Rapid manufacturing materials like SLA (Stereolithography) resins typically offer smooth surface finishes, ideal for visually appealing prototypes, whereas FDM (Fused Deposition Modeling) plastics may introduce textured finishes.

Applications Across Diverse Industries

Fast prototyping materials serve a wide array of industries, each with its unique needs and applications:

• Aerospace: In the aerospace sector, additive manufacturing materials are pivotal in developing aircraft components, engine parts, and even spacecraft prototypes. These materials must adhere to strict standards concerning strength, durability, and lightweight properties.
• Healthcare: Healthcare leverages quick prototype materials for crafting patient-specific medical devices, including personalized prosthetics, orthodontic aids, and anatomical models for surgical planning.
• Automotive: The automotive industry relies on rapid prototyping materials to fabricate functional prototypes for vehicle design. This enables engineers to test and refine various automotive components, encompassing interior features and mechanical parts.
• Consumer Electronics: Rapid prototyping materials are indispensable in consumer electronics, facilitating swift iterations of electronic device casings. These materials must strike a balance between aesthetics, durability, and functionality.
• Industrial Design: Industrial designers harness quick prototyping materials to assess their product designs&#; ergonomics, aesthetics, and functionality. This makes sure the final product matches what users want and what&#;s needed for making it.

Designing Prototypes with the Right Materials for Fast Prototyping

When crafting prototypes for rapid prototyping, essential design considerations can significantly influence your project&#;s success. Let&#;s explore these design factors in more detail:

Material Selection

Opting for the appropriate material is crucial in designing prototypes for rapid fabrication. The selection process involves assessing several factors:

Material Properties

Different fast prototyping materials possess unique traits, such as strength, flexibility, heat resistance, and more. For instance, if you&#;re working on a prototype for a mechanical component, a durable material like ABS would be a wise choice.

Cost-Effectiveness

Your budget plays a significant role in material selection. While high-performance rapid manufacturing materials may offer outstanding properties, they often come at a higher cost. It&#;s essential to balance costs with benefits.

Intended Use

Consider how your prototype will be used. Is it primarily for functional testing, visual evaluation, or both? Prototypes intended for functional testing may require materials that closely resemble the end product&#;s properties.

Layer Thickness

Layer thickness is how thick each layer is when something is 3D printed. This parameter can greatly affect the quality and precision of your prototypes.

Fine Details vs. Printing Time

Smaller layer thickness allows for finer details and smoother surfaces but tends to extend printing time. Striking a balance between achieving desired detail and managing time constraints is crucial.

Support Structures

Complex designs with overhanging features or intricate geometries often require support structures. These temporary structures provide stability during printing and prevent deformities in the prototype using 3D printing filament.

Stability and Accuracy

Support structures ensure your prototype maintains structural integrity throughout printing, especially in areas with challenging geometries, preventing issues like drooping or warping.

Post-Printing Removal

It&#;s important to note that support structures must be removed after the prototype is complete, which may require additional effort.

Post-Processing Needs

Enhancing your prototypes&#; final appearance and functionality can often be achieved through post-processing techniques, refining the prototype&#;s aesthetics and functionality.

Painting

Adding paint can introduce color or texture to your prototype, enhancing its visual appeal or aligning it with your branding.

Sanding and Polishing: Smoothing rough surfaces or edges through sanding and polishing can improve the tactile qualities of your prototype, ensuring a more pleasant user experience.

Cutting-Edge Trends in Rapid Prototyping Materials

Curious to know what is in the world full of rapid fabrication materials constantly evolving, bringing forth exciting innovations and redefining the game. Let&#;s explore these trends that are shaping the future:

Multi-Material Printing

A remarkable stride in quick prototyping is the capability to employ various materials in a single print. This advancement empowers engineers and designers to craft prototypes with diverse traits and functions.

Imagine creating a single prototype combining stiff and flexible materials, unlocking the potential for intricate designs with differing hardness, flexibility, or even transparency levels. This versatility facilitates a closer replication of the final product&#;s characteristics and performance in one go.

Nanocomposites

Integrating nanoparticles into fast prototyping materials marks a substantial leap forward. Nanocomposites elevate material properties in diverse ways. By introducing nanoparticles like carbon nanotubes or graphene, materials can gain enhanced strength, electrical conductivity, and flame resistance.

These improvements are particularly beneficial in industries such as aerospace and electronics, where rapid manufacturing materials must meet stringent performance benchmarks. Nanocomposites pave the way for lighter, more durable, and safer prototypes.

Biocompatible Materials

In healthcare and biotechnology, the advent of biocompatible materials is a game-changer. These materials are meticulously designed to be safe for use inside the human body, making them ideal for applications like medical devices, implants, and tissue engineering.

Biocompatible quick prototyping materials empower engineers to fashion prototypes that closely emulate human tissues or organs, revolutionizing patient-specific treatments and advancements in healthcare.

Sustainable Materials

With an increasing focus on sustainability, environmentally-friendly rapid prototyping materials are gaining prominence. These materials aim to diminish the ecological impact of the prototyping process while upholding essential performance standards.

For instance, some sustainable materials originate from renewable sources or are readily recyclable. This shift towards sustainability aligns with the industry&#;s commitment to reducing waste and curbing its carbon footprint, solidifying its significance in quick prototyping materials.

How to Choose the Ideal Material for Quick Prototyping?

Picking the perfect material for your rapid prototyping endeavor is a crucial decision that can significantly influence your project&#;s outcome. Here&#;s a practical approach to help you navigate the material selection process:

Understand Your Project Needs

Start by thoroughly grasping the requirements of your project. Consider factors like intended usage, durability, resistance to temperature, and any specific mechanical properties required. A solid understanding of your project&#;s demands is essential for making well-informed material choices.

Align Prototyping Material with Production Resin

If you&#;re dealing with plastics, consider finding the best fast prototyping material that closely matches the resin you intend to use in production. This approach ensures that your prototype mirrors the characteristics and qualities of the final product. Testing various prototyping materials against the production resin can aid in identifying the best match.

Account for Material-Specific Design Considerations

When working with metals, design considerations become pivotal. Depending on the chosen metal, you may need to adapt your design to accommodate specific joining or machining processes. For instance, welding stainless steel is relatively straightforward, while working with aluminum demands distinct design approaches for effective joining.

Follow a Strategic Material Selection Approach

A useful material selection strategy involves two primary considerations: material attributes and function. Initiate the process by screening and ranking material attributes pertinent to your design.

This encompasses mechanical, thermal, and electrical properties, including ease of procurement and manufacturing costs. Establishing property limits at this stage helps eliminate unsuitable materials.

Optimize Performance Using Material Indices

To further fine-tune your material choices, maximize performance by considering material indices. These indices amalgamate two or more material attributes to evaluate how well a material aligns with your performance objectives.

For example, if your goal is to enhance the performance of a spring, assess each material&#;s failure stress divided by Young&#;s modulus. Material property charts can simplify this analysis, aiding in identifying quick prototype materials that meet your criteria.

Consider Supplementary Information

Don&#;t overlook supporting information about each material that might not be quantifiable through properties alone. This supplementary data may encompass availability, pricing, corrosion resistance in specific environments, sustainability, and compatibility with machining processes.

Material data sheets, online research, reference books, and textbooks can furnish valuable insights.

Develop a Bill of Materials (BOM)

Once you&#;ve made your material selections, creating a Bill of Materials (BOM) is imperative. This document delineates the materials for production, ensuring alignment among engineers, procurement personnel, and manufacturers. Ensure that raw materials are accurately detailed in the BOM to facilitate effective supplier communication and maintain cost oversight.

Conclusion

In summary, the choice of the right material for rapid prototyping holds a pivotal role in the success of your project. By comprehending your project&#;s requirements, aligning materials with production resins, and adhering to a structured selection strategy, you can optimize your prototypes and lay a solid foundation for efficient production.

 For all your CNC machining and prototyping needs, consider Prototool&#;a reliable partner ready to bring your designs to fruition with precision and expertise. Elevate your production with Prototool today.