Rapid Prototyping

A rapid prototype is a full-scale functional form of a new product. MDI offers Stereolithography (SLA) and Selective Laser Sintering (SLS) as well as machining. SLA and SLS technologies can produce a prototype in hours if a 3-D model is available. If a 3-D model isn't available, it isn't difficult to produce one from a dimensioned drawing. Stereolithography is a free form fabrication method that has become the most popular prototyping technology. It uses photo-curable liquid in combination with a laser. Selective Laser Sintering is also a layered manufacturing process, but it uses powdered materials with a CO2 laser. Producing prototypes allow for critical elements of a design to be tested before moving forward to production. Prototyping usually allows product designs to be improved as the prototype shows problems areas before final production.

How Rapid Prototypes Save Time and Money

1) Prototypes can be used to confirm product fit and function. Many design issues can be identified and corrected during this stage. Having a functional part allows deeper understanding of design and enhances innovation.

2) Prototypes can also be used for marketing and customer response. A product can be validated by end-user to ensure a positive market response before the final product is delivered.

3) Prototyping is a way to test many concepts quickly and inexpensively. Product development can often involve many failures before the best product is finally produced. Rapid prototyping can be done in a matter of hours if 3-D model is provided.

Stereolithography is a layered manufacturing method that uses photo curable liquid resin in combination with an ultraviolet laser. When the laser passes over the curable resin, it hardens the surface of what will become a layer of the formed part. Each layer is formed in 0.002" to 0.004" steps until the part is complete. Selective Laser Sintering (SLS) is another rapid prototyping process that offers improved physical properties compared to stereolithography (SLA). Selective Laser Sintering (SLS) rapid prototypes are made in layers like SLA, but instead of a curable liquid, SLS uses powdered material that is fused with a CO2 laser. A thin layer of powder is laid down and the CO2 laser draws on the powder, sintering the particles together. Layers are produced in 0.004" steps until the part is complete. Once the SLS part is complete, it will be a durable and functional part that can be finished and painted.

Sterolithography (SLA) vs Selective Laser Sintering (SLS)

Stereolithography (SLA) offers high accuracy and excellent finish, but offers moderate strength. Selective Laser Sintering (SLS) is strong and offers a variety of materials to closely match the final production material. The finish isn't as good as SLA, but SLS models can be decorated. MDI can also can machine prototypes if the application requires.

Picking The Right Prototyping Technology

Determining the right prototyping technology that is the least expensive and best suited for your requirement can be challenging. Stereolithography (SLA) is a good fit if the dimensions are critical and part function isn't required. SLA models tends to be brittle and can break under moderate loads. Selective Laser Sintering prototyping is strong and can be made with different base materials closely resembling material in final production. SLS is an excellent choice for functional testing and can be done with large parts. SLS parts can be decorated as needed. If you have any questions about rapid prototyping, please use our contact form and a MDI representative will contact you regarding your prototyping needs.

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