Rapid Prototyping (RP) utilizes various manufacturing techniques to quickly create physical parts directly from CAD model data. Rapid prototyping helps apply at any stage of the product development cycle for any component or subcomponent. Prototypes can be repeatedly reproduced during the design process of a new product.
What is rapid prototyping and 3D printing
Is rapid prototyping the same as 3D printing? The simple answer is: no. However, in today's product development process, which can be used first from the above is often used in conjunction with terms such as "3D printing" and "additive manufacturing", mainly because 3D printing first gained significance as a means of rapid prototyping. However, many additive manufacturing techniques have moved forward and made huge strides in producing high-quality parts, which may not be the first choice for some prototypes due to the higher cost of 3D printing.
Difference between rapid prototyping and 3D printing
3D printing or additive manufacturing is a production process, while prototyping is the result or end product. Additionally, 3D printing itself or other processes can be used to create rapid prototypes. Why is rapid prototyping such an attractive solution for the market? Companies need to develop and introduce new products faster and faster to remain competitive in today's dynamically changing consumer market. As rapid development and technological innovation are key to a company's success, rapid prototyping becomes the most important element in the development of a new product. Moreover, such methods make it easier to achieve the following goals:
- Faster development — prototyping plays a key role in creating a successful product, as it accelerates the process of creating a new product,
- Early design/concept phase — this includes verification of form, fit, and function of the project,
- Product verification in the final phase in terms of technical requirements and business objectives,
- Enabling functionality testing to verify concept assumptions and finalize the product,
- Prototypes provide end users, customers, recipients, project participants with practical experience to obtain feedback.
Additionally, it is worth highlighting the derivatives of this field's development, which include, among others:
- Applications for rapid prototyping,
- Visual prototypes,
- Conceptual models,
- Functional prototypes,
- Pre-production prototypes,
- Tools for prototype production,
- Forms for prototype production.
Advantages of rapid prototyping
- Faster realization and concept testing
Rapid prototyping transfers initial ideas into low-risk concept exploration that in the blink of an eye look like real products. It allows designers to go beyond virtual visualization to more easily understand the look of the design and compare concepts with each other.
- Effective communication of ideas
Physical models allow designers to share their ideas with colleagues, clients, CNC operators, and superiors in a way that would not be possible through screen-based project visualization alone. Rapid prototyping facilitates the delivery of clear, practical feedback from users, which programmers/designers/CNC operators need to understand user needs, and then refine and improve their designs.
- Iteration of projects and immediate implementation of changes
Designing is always an iterative process, requiring numerous rounds of testing, evaluation, and refinement before reaching the final product. Rapid prototyping with 3D printing, or using CNC machines, streamlines this critical trial and error process, providing flexibility in more conveniently creating more realistic prototypes and instantly implementing changes. A good model is a 24-hour design cycle, which consists of: dynamic design, creating prototype parts using CNC at night, corrections and tests the next day, modifications and so on until successful.
- Cost and time savings
Thanks to 3D printing, expensive tools and configurations are not needed, the same equipment can be used to produce different geometries. Rapid prototyping in-house eliminates the high costs and time of implementation associated with outsourcing.
- More accurate testing and minimization of design flaws
In design and production using CNC machines, early detection and repair of design defects can help companies avoid costly project rework and tool changes in the future. Rapid prototyping allows engineers to accurately test prototypes that look and function like end products, reducing the risk of usability issues before they are introduced into production.
CNC Machining vs. Rapid Prototyping - Pros and Cons
In the case of parts whose function depends on high precision and tolerance, CNC machining remains the best available prototyping method. CNC processes are a subtractive manufacturing process, where blocks and rods of metal and plastic are milled and turned to produce very precise, complex parts. There are many materials available that suit every application. For rapid prototyping of CNC parts, only the critical features of the parts that need to be machined and broken down are considered.
Benefits:
- Excellent precision and surface finish,
- Many material options,
- High durability and the ability to perform various functional and environmental tests.
Disadvantages:
- Geometric limitations,
- Expensive due to configuration and tooling costs,
- Very limited internal capabilities due to equipment costs.
Which projects are worth choosing for fast CNC prototyping
CNC prototyping has many advantages. The main ones are outlined below:
- Digital physical prototype:
In CNC prototyping, digital images or prototype stimuli are created. The model will only be produced when the digital stimulus has shown the appropriate prototype function. This helps to ensure that the prototype is built according to the specification.
- Precision and consistency:
In CNC prototyping, CAD models of required dimensions are created. It is possible to make many changes in dimensions until the operator receives exact output data on the screen. CNC machines ensure the production of prototypes with precise accuracy of CAD models. Many prototypes of different designs can be repeatedly manufactured using CNC machining.
- Material compatibility:
Unlike 3D printing, CNC prototyping is an attractive option if you are working with various engineering materials. Since the CNC process is used for prototypes requiring mechanical strength, it allows the use of materials such as aluminum, steel, stainless steel, PPE, HDPE, etc. The materials used in CNC prototyping include both construction metals and construction polymers.
- Continuous production:
CNC machines work 24/7 without the need for human intervention. If prototype construction is time-consuming, the operator can set the parameters, and the machine will perform the task precisely. This makes rapid prototyping in CNC machining a significant time-saver.
- Visual and functional accuracy of the final product:
CNC prototype production results in prototypes that closely resemble the desired outcome. This means that the visual and functional similarity of CNC prototypes is very good, allowing product engineers to envision what the final product will look like. This, in turn, makes their testing efficient.
- Comprehensive prototyping:
Unlike additive manufacturing methods, CNC machining is suitable for complex product manufacturing. It gives designers the freedom to design complex prototypes. Since it is a subtractive manufacturing process, removing material helps in refining the details of the machined item. Therefore, rapid prototyping in CNC machining facilitates improvement.
Although CNC machining is a highly automated process, it only yields the desired results when performed by experts. Marking, material considerations, CAD design, and machine availability make it a job for professionals. Therefore, one should only purchase rapid CNC prototyping from trusted industry experts.