Basic Principles of Rapid Prototyping Technology
In the past decade, with the formation of a globalized market, the competition in the manufacturing industry has become increasingly intense. Particularly, the rapid proliferation of computer technology and the widespread application of CAD/CAM technology have led to the extraordinary and rapid development of Rapid Prototyping (RP), demonstrating strong vitality and broad application prospects.
Traditional processing technologies involve material removal methods, where excess material is removed from a workpiece to obtain the desired product. In contrast, the basic principle of rapid prototyping technology is to construct a three-dimensional digital model of the target part using computer or 3D scanning systems. This information is then transmitted to a computer-controlled electromechanical system. The computer processes the model by “slicing” it into layers of a certain thickness, meaning that the 3D data of the part is discretized into a series of 2D contour information. Through an additive manufacturing method, materials are deposited layer by layer to build the physical part. Finally, minimal post-processing and heat treatment are carried out to ensure that the part’s performance and dimensions meet design requirements.
Rapid prototyping integrates mechanical engineering, CAD, reverse engineering technology, layered manufacturing technology, numerical control technology, materials science, and laser technology. It allows the automatic, direct, rapid, and precise transformation of design ideas into functional prototypes or directly manufactured parts. This provides an efficient and low-cost means for prototype making and the verification of new design concepts.
Currently, there are dozens of rapid prototyping processes, which can be roughly divided into seven categories: stereolithography, laminated object manufacturing, selective laser sintering, fused deposition modeling, 3D welding, 3D printing, and digital light processing. The basic principles are illustrated in the diagram below.
Application of Rapid Prototyping Technology in Product Development
Continuously improving the application level of RP technology is an important aspect of promoting its development. Currently, institutions like the School of Mechanical Engineering at Xi’an Jiaotong University, the National Engineering Research Center for Rapid Prototyping, and the Ministry of Education’s Rapid Prototyping Engineering Research Center have applied rapid prototyping technology extensively in various fields. These fields include industrial design, mechanical manufacturing, aerospace, military, architecture, film and television, home appliances, light industry, medicine, archaeology, cultural arts, sculpture, and jewelry. As this technology continues to evolve, its application areas will continue to expand. The practical applications of RP technology are primarily concentrated in the following aspects:
Application of Rapid Prototyping Technology in Product Development
Rapid prototyping (RP) technology is widely applied in the design and trial production of new products. The main applications are as follows:
- CAID Application:
- Industrial designers can quickly obtain accurate prototypes for design discussions and evaluations with stakeholders.
- Mechanical Design Application:
- It is used for interference verification and early detection of design errors, reducing the need for later modifications to molds.
- CAE Effectiveness:
- Functional molds are created using functional materials through rapid tooling technology for product functionality testing and analysis.
- Visual Effect:
- Designers can see the initial prototype of their design within a short time, providing a foundation for further development.
- Design Confirmation:
- Prototypes can be completed quickly, giving designers ample time to conduct detailed verification of the product design.
- Replication for Optimized Design:
- Multiple components can be produced simultaneously, allowing each to be tested against different design requirements to achieve optimal design in the shortest time.
- Direct Production:
- Directly produces small tools or serves as a mold for replication.
Rapid Tooling and Rapid Casting
Traditional mold production is time-consuming and costly. Combining rapid prototyping (RP) technology with traditional mold manufacturing techniques can significantly shorten the development cycle of mold production and improve productivity. This approach effectively addresses the weaknesses in mold design and manufacturing. The application of rapid prototyping technology in mold manufacturing can be categorized into direct tooling and indirect tooling.
- Direct Tooling:
- Involves using RP technology to directly build the mold through layer-by-layer deposition.
- Indirect Tooling:
- Involves first creating a rapid prototyping part, which is then used to produce the desired mold through replication.
Mechanical Manufacturing:
Due to the unique characteristics of RP technology, it has gained widespread application in the field of mechanical manufacturing, particularly for producing single or small batch metal parts. For some special and complex components that require only single-piece production or small batches of fewer than 50 pieces, RP technology can be directly used for molding. This approach is cost-effective and has a short production cycle.
Rapid Prototyping Technology in Medicine:
In recent years, there has been extensive research on the application of RP technology in the medical field. Based on medical imaging data, RP technology can be used to create models of human organs, which have significant applications in surgical planning.
3D Replication:
Rapid prototyping manufacturing technology is widely used in artistic creation, artifact replication, digital sculpture, and more.
Aerospace Technology:
Aerospace products are characterized by complex shapes, small batch sizes, varying part specifications, and high reliability requirements. The process of finalizing these products is complex and precise, often requiring multiple rounds of design, testing, and improvements, which are costly and time-consuming. Rapid prototyping technology, with its flexible and diverse processing methods and technical advantages, holds unique application prospects in the development of modern aerospace products.
Home Appliance Industry:
Rapid prototyping systems have been widely adopted in the domestic home appliance industry, helping many companies to lead the market. For example, companies like Midea, Hualing, and Kelon in Guangdong; Chunlan and Little Swan in Jiangsu; and Haier in Qingdao have all successively adopted rapid prototyping systems to develop new products, achieving excellent results. The application of rapid prototyping technology is very extensive. It is believed that as rapid prototyping manufacturing technology continues to mature and improve, it will be promoted and applied in more and more fields.
