Press Release
Time Warp for Rapid Prototyping
How fast is fast enough? Rapid prototyping is pushing the boundaries outward…with new technologies and strategies to produce prototypes at higher speed
Many began speculating with the development and introduction of stereolithography (SLA) technology back in the late 1980’s…could drive-thru manufacturing be far behind? Place an order for parts at one window, pick them up at the next. After all, SLA devices were capable of producing highly accurate models of parts within hours or days, instead of the typical weeks or even months previously required through crafting models manually by clay sculpting or wood carving. With SLA and the numerous technologies that have since followed, including laminated object manufacturing, selective laser sintering, fused deposition modeling and others, the label ‘rapid prototyping’ has been used to describe this new industry sector.
Even so, in the end, these so-named “rapid prototyping” technologies still produce only a model—made of plastic, wood-like paper, powdered metal—which is not a true prototype part. What’s more, they reveal little if anything about the production processes, the tooling and fixtures, or the machines—the manufacturing intent of the proposed component and its design. Questions like production quantities, quality tolerances and mechanical properties may go unanswered until later in the launch process when delays and changes become more expensive.
Then, in 1991, a new company, 3-Dimensional Services, was founded that set out to redefine rapid prototyping, and to make drive-thru manufacturing a reality (or as close to it as technologies make possible). Today, thanks in part to their efforts, rapid prototyping is likened to a frame of mind, encompassing more than just making part models. You can now actually broaden the scope of rapid prototyping to envision the entire process included in producing a prototype part.
Rapid prototyping is no longer limited to any one technology or methodology, but rather, it uses all available resources to make a completed prototype part in significantly less time than traditional prototype manufacturing would require. To meet this accelerated guideline, a rapid prototype firm has to be agile, both in its physical plant facilities and its thought processes.
Back in the early days at 3-Dimensional Services, “rapid and fast” were relative terms tied closely to the technologies available at the time. Laser processing centers for both cutting and welding applications were a large part of the firm’s initial capital investments (and still remain a major contributor to its operation). Thus, the first projects reflected these capabilities, as demonstrated with armor plating being cut for law enforcement vehicles, and in steel plating being transformed into a system for transporting a real grass playing surface indoors for World Cup soccer matches. Of course, technologies have advanced new materials developed and additional resources have been acquired. As they have evolved, lead times have been condensed. The many applications tell a story of enhanced prototype build performance.
Take for example one of 3-Dimensional Services early forays into plastic molding in the mid 1990’s…a prototype nylon automotive intake manifold. In the days of downsizing and weight reductions, cast iron manifolds, weighing as much as 90 to 100 pounds were initially replaced by aluminum alloys weighing in at 25-30 pounds. Then, work began on the first generation of phenolic manifolds with weights of 10 pounds. 3-Dimensional Services’ work with these parts took them from CAD file to production-ready in just 2-1/2 months…a feat that, at the time, would typically have required eight months to one year.
Other numerous applications demonstrate a continuous downward trend in development and prototype lead times.
- A project involving approximately 25 plastic ‘A’-surface (visible) parts such as tray tables, and some 10 stamped or machined structural components, including arm rests and supports, for the aerospace supplier. Past experience had shown this type project has takes up to eight months to finish—3-Dimensional Services delivered metal structural components and injection mold tooling in less than six weeks.
- Another project involved an automotive door handle locking assembly, and among the 65 different prototype parts to be made were ratchets, pulls, lever releases, actuator covers, frame brackets and linkages. Of the parts, approximately 60% were to be injection molded acetone-based plastics, and the remaining 40% were stampings. The client requested a minimum of 15 pieces of each part. A competitive prototype shop quoted 5-6 weeks to complete the prototypes, 3-Dimensional Services said one week…and delivered. 3-Dimensional Services then proceeded to finish the opposite door’s mechanism in a like time frame. 3-Dimensional Services was assisted in the above work by its affiliate company, Urgent Plastic Services (UPS), which was formed to specialize in the rapid prototyping of plastic injection molded components.
- Developments in the personal audio electronics market happen fast and furious. For one audio components manufacturer that meant getting its digital audio receiver launched quickly. It took 13 days from the time 3-Dimensional Services was provided with the customer’s original CAD files for the seven different components to delivery of injected molded first-off parts. Within two months, the company had completed nearly 5,000 approved components for the DAR launch and beta testing.
- With a trade show deadline looming, an outdoor leisure company turned to 3-Dimensional Services’ rapid prototyping capabilities to produce eight different parts for a new gas barbecue grill, including stampings and deep-draw stampings plus casting of components…all of which were required in just three weeks. The fast turnaround encompassed stereolithography modeling, CAD-to-CAM programming transfer, high speed machining of stamping dies, mold construction for the foundry tools and casting, hydraulic press forming, 5-axis laser trimming.
- From Urgent Plastic Services (UPS) is the application of producing headlamp assemblies in a fast and efficient turnaround. With approximately 20 design modifications made in 18 months, that works out to an average of a new prototype every month or so, consisting of the headlamp lens (molded polycarbonate), the parking light/turn indicator lens (molded acrylic), park/turn reflector (bulk molding compound), the headlamp housing (talc-filled polypropylene), and the headlamp bracket (polybutylene).
Today, however, the demand for such impressive short-time deliveries is being surpassed by new technologies and strategies put in place by the prototyping companies. Recently, UPS responded to an emergency need for supplying a prototype multi-port automotive fuel pump component by delivering it in just two days. This accomplishment is made even more significant by the fact that the client had 20 potential designs…each was first modeled on a SLA system for fit and function testing. Once a design was approved, tooling was machined and finished injected molded prototypes furnished by the second day. In addition, the tooling design was used to fabricate production tooling, and approximately 150,000 pieces were then produced.
A second recent example, also involving UPS, introduces a new and innovative strategy of modifying existing production pieces to achieve desired prototype results. The project required a redesign of tail light assemblies for a SUV model, incorporating new reflex (reflectability) patterns and bulb placements and back plates, needed for an exhibit to design review teams. Only one tail light assembly was needed, but in a short week’s time.
To complete the job, UPS used a production tail light lens, removed the existing reflex configuration and inserted the new, simulated reflex pattern. The simulated pattern, a series of prism-like surfaces on the lens, was machined using high-speed CNC machining centers. Although UPS has in the past produced lenses with true reflex patterns, considering the time frame, the economies of one piece/assembly being required, and the usage of aesthetic review only, the simulated reflex proved more than adequate for this situation.
And the list continues…fixtures for LeMans race car body panels in five days, toy boats, modeled and modified in just weeks, plastic rear automotive fascias measuring approximately 73" x 16" x 18" and 0.118" thick, low pressured RIM molded in a four week turnaround, and complete auto frame build capabilities…some with over 130 individual components, nearly 40 sub-assemblies, and with 12 variations of side rails and 14 different upper and lower cross members (28 total)…all within 15 weeks. It’s the new time, the new age and the new strategies in rapid prototyping.
3-Dimensional Services, along with subsidiaries Urgent Plastic Services and Urgent Design & Manufacture (specialist in prototypes for stamping, forming and assemblies), provide prototype services for virtually all process disciplines including laser cutting and welding, machining, stamping, hydroforming and tube bending, plastic injection molding, vibration welding, castings, RIM tooling, SLA, LOM and SLS rapid modeling, high definition stamping of exotic alloys, and assembly operations.
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