Rapid Prototyping
What is Rapid Prototyping?
Rapid prototyping is a process that involves quickly creating a scaled-down version or model of a product or system to test its design and functionality, which is typically achieved by using digital tools like 3D printers and computer-aided design (CAD) software.
Rapid prototyping is often used in product design and development to help refine and improve the design before moving into full-scale production. This allows designers and engineers to test and refine their ideas and make changes early on, ultimately leading to a better final product.
- Quick design testing
- Reduced costs
- Improved products
How Does Rapid Prototyping Work?
Rapid prototyping typically involves steps, starting with creating a digital model using computer-aided design (CAD) software. This digital model is then input into a fast prototyping machine, which uses various methods such as 3D printing, CNC milling, or laser cutting to create a physical prototype of the design.
The machine reads the digital model and creates a physical replica by depositing layers of material until the final product is created. The process can be repeated quickly and at a relatively low cost, allowing designers and engineers to create multiple iterations of the product design and make improvements based on each prototype.
Once the physical prototype is created, it can be tested for its design and functionality. Any changes can be made to the digital model, and a new prototype can be created, repeating the cycle until the final design is approved.
Our Qualification for Rapid Prototyping Service
At JIAHUI, we have a team of highly qualified experts who specialize in providing top-notch rapid prototyping services to our clients. Our team comprises experienced designers and engineers skilled in using the latest digital tools and technologies to create highly accurate and precise prototypes.
We offer various prototyping methods tailored to suit our client’s specific needs. Our prototyping methods include 3D printing, CNC machining, injection molding, vacuum casting, and laser cutting. We use the highest quality materials, such as plastics and metals, to ensure our prototypes meet our client’s specifications.
Manufacturing Process
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Pre-processing
- Construction of 3D model
- Approximate processing of 3D model
- Selection of model forming direction
- 3D model slicing
Layered and superimposed free forming
The production of the model section profile and the superposition of the section profile
Post-processing
- Stripp ing or unsupporting of the workpiece
- Post-curing
- Repairing
- Grinding
- Polishing
- Surface strengthening treatment
Types of Rapid prototyping
Rapid prototyping can be categorized into various types. Each method enables the manufacturers to produce fast and cost-effective prototypes with multiple materials and complexities. Different kinds of rapid prototyping aid in efficiently developing automotive and other components.
Rapid CNC Machining Process
Rapid CNC machining uses CNC machines to quickly and accurately fabricate automotive parts from various materials. Its precision and speed make it ideal for producing complex and custom automotive parts with tight tolerances and intricate geometries. The process involves cutting tools to remove material from a block or sheet of the chosen material, resulting in high-quality finished parts suitable for various automotive applications.
Rapid Injection Molding Process
Rapid injection molding is a cost-effective process that uses the high-pressure injection of thermoplastics or thermoplastic elastomers to produce automotive parts in no time. Materials like ABS, PMM, PPS, HDPE and PP are commonly used for strength, durability, and heat resistance. It is ideal for prototyping, testing, and producing small to medium-scale interior and exterior automotive components.
Rapid 3D Printing Processes
Rapid 3D printing is a manufacturing process that uses additive technology to swiftly form automotive parts by layering materials in a precise manner. This process allows for fast prototyping, functional testing, and small-scale production of complex parts with customized geometries, making them suitable for automotive components. Plastics and metals are the most famous materials for Rapid 3D printing techniques.
Rapid Sheet Metal Fabrication
Rapid sheet metal fabrication is a manufacturing process that rapidly creates automotive parts from sheet metal materials such as steel, aluminum, and stainless steel. The process typically involves cutting, bending, and assembling sheet metal using advanced techniques like laser cutting and CNC bending. Rapid sheet metal fabrication is commonly used for producing automotive components such as brackets, housings, enclosures, and panels.
Rapid Vacuum Casting Process
Rapid vacuum casting is a manufacturing process that uses silicone molds to quickly produce small to medium-sized automotive parts with high-quality surface finishes and details. It involves pouring liquid casting materials, such as polyurethane resins, into a silicone mold and then subjecting it to vacuum pressure for efficient curing. Vacuum casting can produce varying degrees of flexibility or rigidity in various colors.
Rapid Urethane Casting Process
Rapid urethane casting swiftly manufactures automotive parts using silicone elastomer molds and polyurethane resins. Urethane casting is only suitable for low-run and medium-run productions. This process is faster and cheaper as compared to injection molding. The materials used in Urethane casting are Nylon, ABS, and PC.
| Material | Weight | Size Limit | Surface Finish | Melting |
|---|---|---|---|---|
| Carbon Steel/Alloy Steel/Stainless Steel |
0.02-220 lbs/0.01-100 kg
|
24″x24″x24″/ 600x600x600mm | Ra6.3 (Ra3.2 achievable if specified) | Air Melting/ Gravity Pouring |
| Aluminum Alloy | 0.03-30 lbs/0.02-15 kg | 16″x12″x12″/ 400x300x300mm | Ra6.3 | Air Melting/ Gravity Pouring |
| Stainless Steel/Low Alloy Steel | 0.02-100 lbs/0.01-45 kg | 24″x24″x24″/ 600x600x600mm | Ra3.2 (Ra2.8 achievable if specified) | Air Melting/ Gravity Pouring & Rollover Pouring |
| Carbon Steel/Alloy Steel/Stainless Steel | 0.02-220 lbs/0.01-100 kg | 24″x24″x24″/ 600x600x600mm | Ra6.3 (Ra3.2 achievable if specified) | Air Melting/ Gravity Pouring |
| Carbon Steel/Alloy Steel/Stainless Steel | 0.02-220 lbs/0.01-100 kg | 24″x24″x24″/ 600x600x600mm | Ra6.3 (Ra3.2 achievable if specified) | Air Melting/ Gravity Pouring |
Our Rapid Prototyping Capabilities
Rapid prototyping is our top choice for manufacturing low-volume metal and plastic parts. Thanks to the high precision, sharp tolerance, and fast lead time of the rapid prototyping process, we can create outstanding parts to meet our customers’ demands. Our highly skilled technicians always strive for the quality of the products.
Materials for Rapid Prototyping
We offer a wide range of metals and plastics for rapid prototyping. The materials are typically selected according to the manufacturing needs of the particular product, as every material has different physical and chemical properties.
- Metals
- Plastics
Metals
MetalsMetal is a solid, lustrous, ductile, and malleable material with excellent conductivity. However, there are over 100 metals, each featuring different physical and chemical characteristics. Hence, the application of each metal varies. Some standard technologies that create metal parts are CNC machining, 3D printing, casting, and more.
Characteristics
- An excellent conductor of heat and electricity
- Good ductility
- High tensile strength
- Shiny appearance
- High melting points
Plastics
PlasticsPlastics are synthetic materials made of polymers. Plastic is a vast term that covers various synthetic materials. The convenience of insulation, shaping, go, od wear and chemical resistance, and lightweight are popular properties that make plastics ideal for rapid prototyping. Examples of plastics are ABS, PC, PU, HDPE, PVC, and PE.
Characteristics
- Lightweight
- High strength-to-weight ratio
- Excellent thermal and electricity insulation
- Low thermal and electrical conductivity
- Good shock resistance
Surface Treatment For Rapid Protyping Parts
Once the aluminum part is produced, it may undergo several surface treatment processes to enhance its properties and make it more corrosion-resistant. The following are some suitable finishing processes for aluminum parts that improve both aesthetics and properties of the particular component.
Surface Treatment
Typical Product
Description
Material
Color
Texture
Anodizing
Anodizing improves corrosion resistance, enhancing wear and hardness and protecting the metal surface. This surface finish is widely used in mechanical parts, aircraft, automobile parts, and precision instruments.
Aluminum, Magnesium, Titanium, Zinc
Clear, Black, Grey, Red, Blue, Gold, White, Silver, Purple
Smooth, Matte finish
Bead Blasting
Bead blasting results in parts with a smooth surface with a matte texture. It is used mainly for visual applications and can be followed by other surface treatments.
ABS, Aluminum, Brass, Stainless Steel, Steel
Clear
Smooth, Matte finish
Powder Coating
Powder coating is a type of coating that is applied as a free-flowing, dry powder. Unlike conventional liquid paint, which is delivered via an evaporating solvent, powder coating is typically applied electrostatically and then cured under heat or with ultraviolet light.
Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel
Black, Grey, White, Yellow, Red, Blue, Green, Gold, Vertical stripe
Smooth, Matte finish
Electroplating
Electroplating can be functional, decorative, or corrosion-related. Many industries use the process, including the automotive sector, where chrome-plating of steel automobile parts is common.
Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel
Clear, White, Black, Grey, Red, Yellow, Blue, Green, Gold, Silver, Bronze
Smooth, Semi-matte, Matte finish
Polishing
Polishing is the process of creating a smooth and shiny surface, either through physical rubbing of the part or by chemical interference. This process produces a surface with significant specular reflection, but it can reduce diffuse reflection in some materials.
Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel
Clear
Smooth, Matte finish
Brushing
Brushing is a surface treatment process in which abrasive belts are used to draw traces on the surface of a material, usually for aesthetic purposes.
Aluminum, Magnesium, Titanium, Zinc, Copper, Stainless Steel, Steel
Clear
Smooth, Matte finish
Comprehensive Manufacturing Solutions
Enjoy high-quality rapid prototyping parts by getting excellent manufacturing solutions from our skilled technology experts.
Typical Rapid Prototyping Products
FAQs Related To Rapid Prototyping
A: The mold we make can meet below criteria:
- Hardness: 60 degrees
- Roughness: Ra0.025µm
- Relative error: within ±2.5µm
- Maximum size range of mold grinding: 610X280mm
- Mold precision: ±0.01mm
A: The best machining accuracy we could achieve is:
- Dimensional tolerance: ±0.001mm
- Coaxiality: <0.0015
- Roundness 0.001m: Ra0.05µm
- Machining accuracy: ±0.01mm
A: Our process specification standard mainly includes the following contents:
- Product characteristics and quality standards
- The features of raw and auxiliary materials, and the quality standards that should be met for production
- Production process
- Main technological conditions and semi-finished product quality standards
- The critical points of the production process
- Inspection items and frequency of leading technical, economic, and finished product quality indicators
- The inspection items and frequency of technical process indicators
- Unique equipment characteristics and quality standards
A: Yes. Our company can provide heat treatment services, including annealing, normalizing, tempering, quenching, carburizing, nitriding, carbonitriding, flame quenching, induction heating, etc.
A: Yes. We have long-term cooperative outsourcing factories that can provide surface treatment services, including paint spraying, silk screen printing, pad printing, heat transfer printing, anodizing, passivation, vacuum coating, electroplating, sandblasting, wire drawing, polishing, powder coating, engraving, Ultrasonic welding, etc.
Benefits of Working With Us
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Hear from our clients
Your services are phenomenal. We received our order and were pleased to see that it's exactly what we needed. We loved the precise details we asked for. The cuts are made precisely and beautifully. The surface finish is outstanding, as there are no divots or tool marks on the parts.
I'm impressed by the professional support you offer to me. Thanks for providing a quick solution to my problem. Your customer support team is very cooperative. I appreciate it and hope to get a quick response every time.
Glad to see that you send us the order very soon without sacrificing its quality. Our engineers examined the parts, and they're impressed by your manufacturing. Your services are world-class. We'll surely contact you for future projects.
We're pleased to get our project done at such a reasonable cost. You always focused on the quality of the parts, which matters a lot to us. The metal parts contain perfect holes. We'll continue doing business with your company.
Thanks for providing outstanding custom parts. We really love the way you strive to benefit us by giving beneficial suggestions and solutions. We always love the quality of the material you use to make our products.
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