Prototyping and Rapid Prototyping

7/28/2019 Prototyping and Rapid Prototyping

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A prototype is an early sample or model built to test a concept or process or to act as a thing to be

replicated or learned from. It is a term used in a variety of contexts, including

semantics,design, electronics, andsoftware programming. A prototype is designed to test and trial a new

design to enhance precision by system analysts and users. Prototyping serves to provide specifications

for a real, working system rather than a theoretical one.

Prototyping is a method used by designers to acquire feedback from users about futuredesigns.

Prototypes are used to revise the design for the purposes of reducing costs through optimization and

refinement.

A prototype is a scaled model.

Differences between a prototype and a production design

In general, prototypes will differ from the final production variant in three fundamental ways:

Materials. Production materials may require manufacturing processes involving higher capital costs than

what is practical for prototyping. Instead, engineers or prototyping specialists will attempt to substitute

materials with properties that simulate the intended final material.

Processes. Often expensive and time consuming unique tooling is required to fabricate a custom design.

Prototypes will often compromise by using more variable processes, repeatable or controlled methods;

substandard, inefficient, or substandard technology sources; or insufficient testing for technology maturity.

Lower accuracy/quality. Final production designs often require extensive effort to capture high volume

manufacturing detail. Such detail is generally unwarranted for prototypes as some refinement to the

design is to be expected. Often prototypes are built using very limited engineering detail as compared tofinal production intent, which often uses statistical process controls and rigorous testing.

Advantages of prototyping

May provide the proof of concept necessary to attract funding

Early visibility of the prototype gives users an idea of what the final system looks like

Encourages active participation among users and producer

Enables a higher output for user

Cost effective (Development costs reduced).

Increases system development speed

Assists to identify any problems with the efficacy of earlier design,requirements analysis and

coding activities
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Helps to refine the potential risks associated with the delivery of the system being developed

Various aspects can be tested and quicker feedback can be gained from the user

Helps to deliver the product in quality easily

User interaction available during development cycle of prototype

Reduces development time.

Reduces development costs.

Requires user involvement.

Developers receive quantifiable user feedback.

Facilitates system implementation since users know what to expect.

Results in higher user satisfaction.

Exposes developers to potential future system enhancements.

Disadvantages of prototyping

Producer might produce a system inadequate for overall organization needs

User can get too involved whereas the program can not be to a high standard

Structure of system can be damaged since many changes could be made

Producer might get too attached to it (might cause legal involvement)[verification needed]

Not suitable for large applications

Over long periods, can cause loss in consumer interest and subsequent cancellation due to a

lack of a market (for commercial products)

May slow the development process, if there are large number of end users to satisfy.

Can lead to insufficient analysis.

Users expect the performance of the ultimate system to be the same as the prototype.

Developers can become too attached to their prototypes

Can cause systems to be left unfinished and/or implemented before they are ready.

Sometimes leads to incomplete documentation.

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or

assembly using three-dimensional computer aided design(CAD) data.

Construction of the part or assembly is usually done using 3D printingtechnology. The first techniques for

rapid prototyping became available in the late 1980s and were used to

produce modelsandprototypeparts. Today, they are used for a much wider range of applications and

are even used to manufacture production-quality parts in relatively small numbers.
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Below is from (http://www.padtinc.com/blog/the-rp-resource/rapid-prototyping-faq)

What is Rapid Prototyping?

Rapid Prototyping is a manufacturing technology that quickly builds a prototype part. Many different technologies are

available that are considered Rapid Prototyping, and many can also be used for production manufacturing. Although

most Rapid Prototyping systems use a form of layered additive manufacturing, they can also use a variety of other

methods such as high-speed machining, molding, casting, and extruding.

Rapid Prototyping, often called RP, is rapid prototyping when the entire process of going from a computer design to a

physical model is faster than more traditional manufacturing technologies. Wikipedia has a good article on the

subject.

What is Rapid Tooling and how is it Different from Rapid Prototyping?

The only difference between Rapid Tooling and Rapid Manufacturing is the end use of the parts produced with the

process. Both use rapid prototyping technologies to quickly make a part. But for Rapid Tooling, the part is used in

another manufacturing process as a tool.

What is 3D Printing and how is it Different from Rapid Prototyping?

3D Printing refers to a subset of rapid prototyping that goes directly from a 3D computer model to a prototype with

very little user interaction other than defining some preferences. The process is designed to be as easy as printing

from a computer to paper.

In many ways the name is a marketing label to clearly emphasize the affordability and ease of making prototypes

using systems that are labeled as 3D Printers. It is also meant to appeal to a larger, less engineering and

manufacturing oriented audience.

What are some of the other names for Rapid Prototyping?

3D Printing, layered manufacturing, additive manufacturing, direct digital manufacturing, digital prototyping, digital

fabricator, desktop fabricator, desktop manufacturing, desktop prototyping.

People often use the names of various prototyping techniques to refer to rapid prototyping, and even more often the

acronyms for those technologies. Examples are Stereolithography or SLA and Fused Deposition Modeling or FDM.

What is Layered Manufacturing and why do most Rapid Prototyping Technologies Use it?

Layered Manufacturing builds parts up, one thin layer at a time. Most traditional manufacturing methods start with a

block and remove material, or shapes material using a tool of some kind. Layered manufacturing is often called

Additive Manufacturing because it adds material rather than taking it away or molding it.

The best way to visualize layered manufacturing is to think of taking a real part and chopping it into very thin layers.

Then stack those layers back up one on top of the other. Layered manufacturing does the chopping in a computer

program, and tells a machine how to create each layer.

When and how is Rapid Prototyping used in Product Development?

Rapid prototyping can be used at almost every step in your product development process. At any point where you

need a physical part you can benefit from Rapid Prototyping.

Examples are:

Conceptualization: concept models, marketing mockups

Initial Design: form, fit, and function testing, visualization
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Detail Design: testing, test fixtures, assembly testing, fit, form and function testing.

Production: tooling, mockups for process planning

What are the different types of Rapid Prototyping Technologies and their Advantages and Disadvantages?

Unfortunately there is no one technology that is perfect at everything. The following table is a basic listing of the main

advantages and disadvantages.

TECHNOLOGY ADVANTAGE DISADVANTAGE BEST USE

SLA

(Stereolithography

)

Smooth Accurate Detail Temperature Sensitive,

Brittle, Brittles over Time

Marketing Models Fit

Checks

SLS Durable, Speed on Large

Projects

Rough Surface, Erratic

Accuracy

Functional Models

FDM

(Fused Deposition

Modeling)

Cost Effective Durable True

Plastics

Lower Resolution Weak

Layer-to-layer

Engineering Models

Internal Reviews

POLYJET Adjustable Material Properties

Speed Fine Layers

Weak Material Properties

Cost

Elastomeric Models

Overmold Models

CNC MACHINING Accurate True Materials Long Lead Time Cost Metal Models Precision

Work

What is a STL (STereoLithography) File?

The STL file is a file format developed in the early days of Rapid Prototyping by 3D Systems as a simple and portable

format that could be used across CAD systems to define the solid geometry to be made in a Rapid Prototyping

machine. It is a triangular facet representation, the surfaces of the solid are modeled as a collection of triangles that

share vertices and edges with neighboring triangles. Most CAD tools can output an STL file.STL is also known as

Standard Tessellation Language

STL files describe only the surface geometry of a three dimensional object without any representation of

color, texture or other common CAD model attributes

What is the most commonly used Rapid Prototyping Technology?

For many years the most commonly used technology is Fused Deposition Modeling. Originally only available from

Stratasys, many other providers have adopted the technology. The best way to see how the various technologies

stack up is through the Wohlers Report, an annual summary of the industry.


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Prototyping and Rapid Prototyping