Definitions

Definitions vary and may differ at different organizations, but the definitions below may be used as a starting point.

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Concept Model: a physical model made to demonstrate an idea. Concept models allow people from different functional areas to see the idea, stimulate thought and discussion, and drive acceptance or rejection.

Prototyping Attributes
Speed: turnaround time to convert a computer file into a physical prototype

Appearance: any visual attribute: color, texture, size, shape, etc. 

Assembly/Fit Testing: making some or all of the parts of an assembly, putting them together, and seeing if they fit properly. At the gross level, this checks for design errors, such as placing two tabs at 2 in. spacing and the mating slots at 1 in. spacing. At the fine level, this is a matter of minor dimensional differences and tolerances. Obviously, any test involving tolerances needs to use the actual manufacturing process or one which has similar tolerances.

Prototyping Attributes
Form: the shape of the part: features and size

Fit: how the part mates with other parts

Functional Testing: seeing how a part or assembly will function when subjected to stresses representing what it will see in its actual application.

Prototyping Attributes
Chemical Resistance: resistance to chemicals including acids, bases, hydrocarbons, fuels, etc.

Mechanical Properties: strength of the part measured by tensile strength, compressive strength, flexural strength, impact strength, tear resistance, etc.

Electrical Properties: interaction of electrical fields and the part. This may include dielectric constant, dielectric strength, dissipation factor, surface and volume resistance, static decay, etc.

Thermal Properties: changes in mechanical properties that occur with changes in temperature. These may include thermal expansion coefficient, heat deflection temperature, vicat softening point, etc.

Optical Properties: ability to transmit light. May include refractive index, transmittance, and haze.

Life Testing: testing properties that may change with time and that are important for a product to remain functional throughout its expected life. Life testing often involves subjecting the product to extreme conditions (e.g., temperature, humidity, voltage, UV, etc.) to estimate in a shorter period of time, how the product will react over its expected life.

Prototyping Attributes
Mechanical Properties (fatigue strength): ability to withstand large numbers of load cycles at various stress levels.

Aging Properties (UV, creep): ability to withstand exposure to ultraviolet light with an acceptable amount of degradation; ability to withstand extended applications of forces to the part with acceptable levels of permanent deflection.

Regulatory Testing: testing specified by a regulatory or standards organization or agency to assure parts are suitable for a particular use such as medical, food service or consumer application. Examples include Underwriters Laboratory (UL), the Canadian Standards Association (CSA), the U.S. Food and Drug Agency (FDA), the U.S. Federal Communications Commission (FCC), the International Standard Organization (ISO) and the European Commission (EC).

Prototyping Attributes
Flammability Properties: the resistance of a resin or part to ignition in the presence of a flame.

EMI/RFI Properties: the ability of a resin, part or assembly to shield or block Electromagnetic Interference or Radio Frequency Interference.

Food Rating: approval of a resin or part to be used in applications where it will come in contact with food while it is being prepared, served or consumed.

Biocompatibility: the ability of the resin or part to be in contact with human or animal bodies, outside or inside the body, without causing undue adverse effects (e.g., irritations, blood interactions, toxicity, etc). Biocompatibility is important for surgical instruments and many medical devices.

Summary

Prototype models help design teams make more informed decisions by obtaining invaluable data from the performance of, and the reaction to, those prototypes. The more data that is gathered at this stage of the product development cycle, the better the chances of preventing potential product or manufacturing issues down the road. If a well thought out prototyping strategy is followed, there is a far greater chance that the product will be introduced to the market on time, be accepted, perform reliably, and be profitable.

What is the best way to get a prototype made? The answer depends on where you are in your process and what you are trying to accomplish. Early in the design process, when the ideas are flowing freely, concept models are helpful. As the design progresses, a prototype that has the size, finish, color, shape, strength, durability, and material characteristics of the intended final product becomes increasingly important. Therefore, using the right prototyping process is critical. In order to most effectively validate your design, pay close attention to these three key elements of your design: functionality, manufacturability, and viability.&#;

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If your prototype can faithfully represent the attributes of the end-product, it is by definition functional.&#;These requirements often include such things as material properties (e.g., flame resistance), dimensional accuracy for fit-up with mating parts, and cosmetic surface finishes for appearance.

If your prototype design can be repeatedly and economically produced in a manner that supports the requirements of the end product, it is by definition manufacturable.&#;These requirements include the ability to maintain the functionality of the design as described above, keep the piece-part cost below the required level, and support the production schedule. No matter how great a design is, it will go nowhere if it can&#;t be manufactured. Make sure your prototyping process takes this into consideration.

Finally, even if your prototype design is functional and manufacturable, it doesn&#;t mean anyone will want to use it.&#;Prototypes are the only true way to verify the viability of the design in this sense.&#;If your design can also pass the challenges associated with market trials (e.g., trade show displays, usability testing) and regulatory testing (e.g., FDA testing of medical devices), you&#;re well on your way to a successful product launch.

The Key Aspects of Aluminum Rapid Prototyping

What is Aluminum Rapid Prototyping?

Modern marketing realities and design factors are pushing designers and engineers to the limit. We have to come up with finished products in the least amount of time. Additionally, we have to budget during the design. We use aluminum rapid prototyping to achieve this feat. It comprises of two unique techniques.

• Additive aluminum prototyping
• Subtractive aluminum prototyping

Additive aluminum prototyping

It entails the use of virtual 3D designs to build up a prototype via the deposition of aluminum layers. We develop prototypes from the bottom up. The best examples of additive rapid prototyping are laser sintering and 3D printing.

Subtractive Aluminum Prototyping

This involves the repetitive cutting of material from a solid aluminum block. In this case, we make the prototype from top to bottom. We perform it using CNC machining processes. Examples are CNC milling, CNC turning, and other standard machining processes. It happens to be a faster and more economical process than its alternative.

A Brief about the Features Aluminum and Its Alloys

Aluminum exhibits low density while still providing excellent strength. Surprisingly, its strength surpasses that of steel. Additionally, it offers amazing plasticity and high resistance to corrosion. It is also relatively cheap since it is abundant in nature. This lowers the overhead cost arising from faulty production or bad design. Moreover, we can easily recycle it, which further helps in cheaper manufacturing. It offers high toughness hence less deformation after manufacturing. This makes it an ideal material for prototyping purposes.

How Do We Carry Out Aluminum Rapid Prototyping?

There are a number of traditional and modern techniques of producing prototypes. Here we will be specifically delving into CNC manufacturing processes. The process varies depending on the type of machine we utilize for the CNC of the prototype. It determines the process we can effectively carry out for aluminum prototyping.

Essentially, it involves a CAD product design into the system. It then converts it to vectors, which we read as coordinates. We then proceed to upload the file and trace the vectors. Afterward, we can select the tool and tool path that cuts the block into the desired shape. It can be a .25-inch v-bit or a .75-inch core box bit. We can vary the cutting depth and cutting speed to our liking.

Upon selection of the tool, its speed, and depth, we can then feed the tool path to the CNC machine. You then have the option of cutting outside the vectors, inside it, or tracing it. The cutting method varies depending on the machinist, machine, and design complexity. After converting the vectors to G-code, we can then determine the block&#;s center. We jog the CNC to the center of the block where it touches the face of it. We refer to this point as the absolute zero. The CNC machine proceeds to read off the G-code and commences the prototyping process.

There is one major flaw when it comes to machining aluminum. Its flakes normally adhere to the tool&#;s cutting edge. This decreases its cutting capability hence affecting the prototyping output. Luckily, we have a way of minimizing the chances of aluminum accumulation on the cutting tool. This is by carefully selecting the cutting tool and its material coating.

Aluminum Rapid Prototyping at Creatingway

At Creatingway, we have four major concerns when it comes to aluminum prototyping. These are:

• To ensure there is excellent chip evacuation from the cutting edge
• Make sure that there is minimal adhesion of the aluminum to the cutting edge during machining
• To maintain the core strength of the tool so that it is sufficient enough to counter the cutting forces without failure.

There are different tools that we use during rapid prototyping. They vary from the straight grade (K) of cemented carbides, diamond-based tools to high-speed tools. We can also effectively use enhanced industry-grade 5-axis machines. This machine produces top-notch aluminum prototypes.

Industries and the Development of Aluminum Rapid Prototyping

Many industries utilize aluminum rapid prototyping as a prime prototype manufacturing method. Industries like aerospace, aircraft, automotive, and electronic industries incorporate its use. This is since it can easily handle complex designs with short turnarounds. This makes it an ideal option by any industry seeking to outperform its competitors in the market.

Aluminum rapid prototyping has been drastically improving over the years. This is owing to the rise in technology and emerging manufacturing techniques. Additionally, CNC stands out as the most effective technique of developing aluminum prototypes. We can easily carry it out and it is cost and time effective.

At Creatingway, we have extensive experience in the market with aluminum rapid prototyping. Our well-trained prototyping operators utilize their expertise to manufacture high-grade prototypes. For any further inquiries, simply contact us.

Creatingway is concentrated on CNC machining manufacturing, prototype machining, low-volume manufacturing, metal fabrication, and parts finishing services, provide you the best support and services. ask us one inquire now.

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