3D Printing Expands Rapid Prototyping
Rapid Prototyping 3D Printing Expands Capabilities
Recent advancements in the additive manufacturing process have been beneficial in developing rapid prototyping 3D printing strategies. These new capabilities, which include inserts, core modeling, or multiple materials, can greatly expand prototyping options. In this webinar, we discuss how to use these advanced processes to expand your rapid prototyping 3D printing.
Add inserts during printing
It is now possible to incorporate non-printed elements such as fasteners, electronics, switches, sensors, or even metal sub-structures into a printed part. This means that hardware can be inserted mid-print, allowing it to become completely encompassed by the 3D print process. The ability to add inserts is a key advantage of the FFF (Fused Filament Fabrication) type of 3D printing and can result in fully functional prototypes.
Create unique zones with core modeling
Core modeling is the process of creating multiple zones or cores within a 3D printed object. Inside each core, engineers can specify different print process settings, such as an infill percentage or material type. This can be advantageous for those who need to create strength in a specific section of a model. By using core modeling, a dense infill can be applied to a single core as opposed to the entire part, but without sacrificing print time. The process can also be applied to the use of multiple materials within the same model, with each having their own specific print settings.
Utilize multiple material types
There is an abundance of material types that are available for 3D printers. The ability to utilize these multiple material types for 3D printing allows users to select the right materials for their project. Often this involves using multiple materials in the same print. By applying the core modeling process, multiple materials can then be incorporated into the same model.
Why Rapid Prototyping?
Rapid Prototyping is the process of manufacturing parts quickly from CAD models. It is an integral part of product development and product testing. Prototypes are required for validation, communication, fitment check, and final testing before launching and moving ahead for mass production. When utilized well, rapid prototyping with 3D printing increases the quality of your designs by enhancing communication between the various parties and reducing the risk of building something that no one wants. Rapid prototyping with 3D printing benefits customers with:
- decreased product development time from months to days
- ideas produced quickly and more frequently improved
- in-hand product vision
- final design before costly tooling
- functional samples in any size or number
In addition, engineers can choose from multiple options and levels of accuracy, depending on the stage of the process and the goal of the prototype. This is often referred to as fidelity, or how closely a prototype matches the final product or solution. For example, if a prototype is produced with a high level of visual fidelity from the beginning, users will tend to focus on visual rather than functional details, which could distract from the primary goals. In the video below, our 3DP representative and development engineer discuss the advantages of 3D printing for engineers in the field.
Justifying a 3D printer investment for rapid prototyping
For many businesses prototyping is an expense, not an investment, and therefore hard to justify. They use the mindset that a higher volume of prototyping can only lead to increased expenses. However, with 3D printing there are significant advantages that can benefit rapid prototyping and get your engineering and accounting teams on the same side. The following will help you define potential challenges along with the steps needed to make your case and win!
Making the Case
New equipment costs compete for limited funds that are allocated across the entire company. In order to justify investments in 3D printing technology, you’ll need to build a case that demonstrates tangible results and value to management. This business case or a use case will contain an executive summary, a situational analysis, and a financial justification. Those that have succeeded in building their cases and obtaining approvals offer four strategies that can be used alone or in combination.
- Build on a tiered approach
- First tier– Substitution: Calculate the savings by substituting 3D printing processes for current prototyping work. Compare the results with traditional manufacturing techniques or third-party 3D printing service providers.
- Second tier – Augmentation: Multiply the type of work being done in the substitution tier. Speed, efficiency, and 3D printing capability decreases the time, cost, and effort when making prototypes.
- Third tier – Extension: Utilize something in the product development process that isn’t a current activity. Extension is likely to deliver the most significant value since it is changing and improving processes.
- Target Cost Reduction: Address the cost side of the equation. Current expenses are easier to measure than forecasted sales.
- Address Current Problems: Avoid a hypothetical benefit and instead present a solution to current problems. The strategy is to leverage what corporate management has already accepted as fact. A good example of this is explained in the video below. Listen to our engineer discuss the real-world impact of a 3D printer on product development costs as he shares his experience of creating their own bracketry for the tool room. He compares the traditional way (tool room guy at two days and $50/hour) to the 3D printing method (three hours and $3 worth of plastic).
- Leverage Shared Budgets: When expenses are split across departments, the decision making can shift from corporate management to managers and directors. Since these decision makers are closer to the day-to-day operations, they are more likely to appreciate the value of 3D printing.