Hey all,
There seem to be alot of interest in rapid prototyping and CNC here. So I though I'd put up an FAQ for you guys
. Hope it helps you, and I'll add to it when new questions arise. I will do a CNC FAQ later, as I havent used it as much and I'm still learning. So without further adoodoo, here goes. Oh and if I', wrong on anything please tell me
.
What is Rapid Prototyping?Rapid prototyping (also known as RP and “3D printing”) is the process whereby a digital model is used to generate a physical model. There are several different machines and processes, but the general theory is that a digital model goes in, and a physical version of it comes out.
What can I use it for?In industry, RP is mostly used to generate concepts; it is easier to understand an object if it is physical. This allows designers to evaluate their work and make changes as issues arise. For example, Dyson have several machines on which they can print entire vacuum cleaner designs, stick a motor in them and then test them right there in the studio.
RP can also be used to make masters for casting. This is a simple process whereby the printed master is cleaned up and moulded. Then casts are made from the mould.
It is rare for companies to sell products that have been made in RP; it is expensive and will probably never replace contemporary mass production methods.
Can I buy a machine?Yes, if you have lots of money. A good one will set you back upwards of $100K. There are cheaper ones, and cheaper machines come out every year, but the quality will be far poorer. However, investing in a good RP machine is a good business in itself, and you can make a lot of money by offering RP services.
OK it’s expensive; can someone do it for me?Yes, there are plenty of companies to choose from. Google will return many names and if you shop around you can find a good deal.
What materials are involved?This is very varied. Different machines use different base materials:
Technology Materials
Selective Laser Sintering (SLS) Thermoplastics, metals
Fused Deposition Modeling (FDM) Thermoplastics, Eutectic metals
Stereolithography (SLA) Photopolymer
Laminated Object Manufacturing (LOM) Paper
Electron Beam Melting (EBM) Titanium alloys
3D Printing (3DP) Plasters, other materials
How does it work?It can best be explained using two machine as examples. 3D Printers and Stereolithography machines. 3d printers split the model into vertical layers (the more layers the better the print.) They then literally print each one of the layers on top of each other, just like a normal printer. The layers stick together and come out as a solid object.
Stereolithographers shoot a laser beam into the uncured material and harden a small sphere of the material, it does this to make every surface on the entire model.
How crisp does it print?Again this is hugely varied, and you get what you pay for. The best machine for small intricate prints is the Viper stereolithographer, and this will print parts as small as .15mm. However this machine is expensive to use. My university has a Zcorp machine that prints in plaster, the objects are good, but delicate and crumbly, and they must be sealed with resin after printing. Fine detail is missed entirely. But it’s cheaper. When you are looking to print something, call an RP company and tell them what you want and they’ll help you out.
How much does it cost?Expect to pay a lot. A LOT, usually in the region of a few hundred bucks at least. If you send your model to a company they will give you a quote.
How do I model an object that can be printed?There are many guides on the McNeel site, and there’s a link to one in this section. It’s tricky, but if you model carefully and efficiently it isn’t too hard.
That’s about all I can think of for now, please post your questions and I will try to answer them J.
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