ENGINEERING PDATE
May 2021
sintering are used for example in the aerospace industry. Using the same process, copper can be used in a design wherever good electrical conductivity is required.
Bringing together high speed and freedom of design In addition to the wide selection of materials, the relatively high speed that can be achieved by additive manufacturing for rapid prototyping is one reason why 3D printing enjoys such a good reputation within product development and manufacturing. Whilst the injection moulding process first requires a lot of time and technological effort to be invested in the production of the tooling prior to moulding the parts, the same part can usually be produced directly using 3D printing without any significant effort. The only thing to note is that the design and shape should be optimised for additive manufacturing. If, for example, overhangs are present, it is recommended that they be kept as low as possible by means of an obtuse angle. In this way, the required supporting structures can be kept out of the way so that the material required as well as the costs are reduced.
The step from design to prototype has just become much easier Additive manufacturing also offers far-reaching design freedom, which cannot be achieved for example with injection moulding or CNC machining. For example, due to the way in which a product is manufactured with additive manufacturing, it is possible to implement tunnels or honeycomb structure in the part. In addition, 3D printing means that geometries can be achieved that just cannot be done with any other production method. This fact is often key - especially in the production of prototypes - and gives engineers and designers great freedom in the design of parts that are tailored to specific applications.
Avoiding surprises Since the demands placed on prototypes can differ, it is particularly important that parts made by 3D printing are also checked after production, and some post-processing may be necessary. It makes no difference whether a prototype is made for a first test run for a better assessment of final dimensions, or if a fully functional part is being created directly through rapid prototyping. In both cases, the products produced must not deviate from the original design specification. Specialist test and inspection services are available to prevent any deviations. Suppliers like Protolabs use techniques such as 3D laser scanning technology and coordinatemeasuring devices in the production of additive parts in order to accurately analyse the physical geometries of parts. In this way, volumetric accuracy can be controlled as a final stage and even the slightest deviation from planned tolerances can be detected.
The bottom line Due to digital transformation and the new horizons opening up for industry, the rapid production of prototypes is becoming increasingly important. An idea that has just been invented today can be essential for an entire industry in just a few days. Additive manufacturing already supports this scenario across industries and can also support design teams by providing prototypes quickly - including getting them into unusual places. Using additive manufacturing, the imagination of designers can soar. And that’s what digital manufacturing is all about: the flexibility to think in any direction.
Andrea Landoni, 3D Printing Product Manager, Protolabs EMEA
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