Rapid and right – the future of prototyping is virtual

In the past decade, the use of AM for this purpose has become widespread in medical, aerospace, and consumer goods product development. Yet, engineers that want to use the technique to make a functional prototype for high-performance parts still face challenges that limit its value.

A key advantage of utilising AM for prototyping is the ability to visualise designs efficiently and immediately. However, the true challenge – and opportunity for value – lies in producing a prototype that meets defined quality tolerances and functional performance criteria.

Valuable insight from manufacturing process simulation and, where required, multi-scale material modelling is overlooked, but it is the key to leveraging the potential of AM in rapid prototyping for precision, speed, and waste reduction.

AM is far from infallible – even in the production of relatively simple parts, common issues such as cracking or shape distortion during the manufacturing process can result in defects and have a profound effect on the performance of the final part.

Trial and error could help to iron out issues when manufacturing parts on a large scale, but producing numerous poor prototypes leads to wasted materials, increased costs, and defeats the “rapid” in rapid prototyping for manufacturers that want to get products to market.

Speed is crucial, and printing without forethought can hinder this significantly. 

Read the full article in DPA's March issue