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.
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.&#;
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 need for efficiency and agility in the ever-changing manufacturing landscape has led to the development of innovative processes. One of which is the concept of &#;rapid tooling.&#; Rapid tooling is essential in shortening the product development cycle, allowing manufacturers to quickly take their designs from idea to reality.
Rapid tooling is also known as prototype mold, prototype tooling, and soft tooling. It allows you to obtain parts easily. It stands out for its short molding cycle, low molding cost, simple process, and ease of promotion. Furthermore, rapid tooling can meet specific functional requirements while providing good overall economic benefits.
Read on to learn about the fundamentals of rapid tooling, ranging from its definition to its various applications and benefits.
What Is Rapid Tooling? Various cutting toolsThe rapid tooling process involves swiftly creating molds and tooling for manufacturing purposes. This is a vital aspect of the rapid manufacturing approach, facilitating quicker and more efficient production of functional parts and prototypes. Rapid tooling is an essential link between rapid prototyping and traditional tooling methods. It offers a cost-effective and time-saving solution.
The main goal of rapid tooling is to accelerate the tooling production process. Thereby allowing manufacturers to transition rapidly from the design phase to actual manufacturing. Through advanced technologies like additive manufacturing and CNC machining, rapid tooling makes it possible to produce molds and tools with improved precision and reduced lead time. Below, we will compare rapid tooling to other manufacturing processes in terms of cost, lead time, speed, material, and applications.
Rapid Tooling vs Rapid PrototypingRapid tooling and rapid prototyping play essential functions in the dynamic manufacturing landscape. Each contributes uniquely to the product development journey. Rapid Tooling is concerned with quickly creating production tools to ensure efficient mass production, whereas Rapid Prototyping excels at rapidly creating physical models for design validation.
Here is a table showing the contrast between rapid tooling and rapid prototyping.
Rapid Tooling Rapid PrototypingCostInitial setup costs might be higher because mold costs are required.In the world of manufacturing, the decision between CNC rapid tooling and conventional tooling is important. This is because it can have a significant impact on production efficiency and costs. Rapid production tooling excels in strength and speed, catering to industries with changing demands, whereas Conventional Tooling is the stalwart, providing stability and precision for long-term, high-volume production.
Here is a table showing the contrast between rapid tooling and conventional tooling:
Rapid Tooling Conventional ToolingCostGenerally more cost-effective for shorter production runs.Higher initial costs, potentially economical for large-scale productions.Lead timeSignificantly shorter lead times. It is ideal for quick response to market demands.Longer lead times, especially for complex tooling.It is reliable for large-scale, long-term production.MaterialVersatile in material options, adaptable to different manufacturing needs. Mold is mainly made of metal materials.Supports a wide range of materials, often with more options than Rapid Tooling.It is suitable for diverse production requirements. Mold is mainly made of steel metal.AccuracyGenerally high accuracy, suitable for production-grade tools.Offers high precision and accuracy, particularly for long-term, stable production.ComplexityCapable of handling complex geometries, suitable for intricate tool designs.Well-suited for extremely complex geometries and detailed tooling requirements.ApplicationWell-suited for industries requiring flexibility, rapid adaptation, and small to medium production. It is used for prototype only when the product development project is 90% sure to be successful.Act as sample for test before high and low volume production. Rapid Tooling vs Die Casting Molding Die cast moldStarting the manufacturing journey requires an important choice between rapid tooling and die-casting molding. They both embody distinct approaches to production. Rapid tooling, emphasizing speed and flexibility, contrasts with die-casting molding, known for its efficiency in crafting intricate parts at scale.
Here is a table showing the contrast between rapid tooling and die-casting molding:
Rapid Tooling Die Casting MoldingCostGenerally more cost-effective for shorter production runs.May have higher initial tooling costs but can offer cost efficiency for high-volume production.Lead timeSignificantly shorter lead times, ideal for quick response to market demands.Initial tooling may take longer, but once set up, production lead times are relatively short, making it efficient for large-scale production.MaterialVersatile in metal and plastic material options, adaptable to different manufacturing needs.It is suitable for various metal alloy materials, especially metals like aluminum, zinc, and magnesium.AccuracyGenerally high accuracy, suitable for production-grade tools.It offers high precision and accuracy, making it a suitable for complex and detailed parts.ComplexityIt is capable of handling complex geometries, suitable for intricate tool designs.Ideal for intricate and complex part designs, offering high-detail reproduction.ApplicationWell-suited for industries requiring flexibility, rapid adaptation, and small to medium production.Commonly used for high-volume production of complex parts in industries like automotive, aerospace, and electronics. Rapid Tooling vs Injection Molding Injection molding processEach method has distinct advantages. Rapid tooling, known for its speed and adaptability, contrasts with injection molding, a method known for its efficiency in producing large volumes of intricately shaped plastic parts.
Here is a table showing the contrast between rapid tooling and injection molding:
Rapid Tooling Injection MoldingCostSignificantly less cost due to cheaper mold.May have higher initial tooling costs but can offer cost efficiency for high-volume production.Lead timeSignificantly shorter lead times, ideal for quick response to market demands.Initial tooling may take longer, but once set up, production lead times can be efficient, especially for large quantities.MaterialVersatile in material options, adaptable to different manufacturing needs. Supports a wide range of materials, particularly plastics, and can accommodate various additives for specific properties.AccuracyGenerally high accuracy, suitable for production-grade tools.Gives high precision and accuracy, making it suitable for complex and detailed parts. ComplexityCapable of handling complex geometries, suitable for intricate tool designs.Suitable for complex part designs, providing high detail reproduction.ApplicationWell-suited for industries requiring flexibility, rapid adaptation, and small to medium production.Commonly used for large-scale production of plastic parts across various industries, including automotive, consumer goods, and medical devices. 2 Ways to Make Rapid Tooling CNC lathe processingThere are two common ways to make molds using rapid tooling. They are direct and indirect rapid tooling. This section will explain the two methods and how they can they used in making molds.
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Direct Rapid ToolingThe direct method of rapid tooling involves the creation of both the cavity mold inserts and the actual core. One significant advantage of this approach lies in its capacity to generate tools with geometries that would be challenging to achieve through other means. An example is the conformal cooling technique, where heat dissipation from the mold is uniform, reducing cooling times by approximately 66%. This is achieved by aligning the internal cooling channels with the contours present in the mold cavities.
Indirect rapid tooling uses additive manufacturing master patterns to make a mold or die. Although many technologies are available, &#;soft tooling&#; techniques are the most widely used. Soft tooling method uses silicone molds for plastic parts and sacrificial models for metal investment casting.
Testing and experimentation are the goals of indirect rapid tooling. For example, indirect rapid tooling is a great solution when you wish to test various materials and already have a detailed design. This is so that molds and multiple test tools can be made from the same master pattern with ease.
Here is a table showing the different steps you can use direct and indirect rapid tooling to make molds:
Steps Indirect Rapid ToolingDirect Rapid ToolingStep 1Model the tool or mold using Computer-Aided Design (CAD) software.The materials used for rapid tooling can be classified as soft tooling materials and hard tooling materials.
Soft ToolingSoft tooling is a versatile manufacturing approach that relies on flexible and resilient materials to create molds to produce various parts. Soft tools, as opposed to their rigid counterparts in hard tooling, are made from materials such as urethane and silicone rubber. They offer unique characteristics that make them particularly well-suited for specific applications.
Urethane is a versatile material used in soft tooling. It is known for its unique combination of flexibility and durability. Because of its exceptional flexibility, it is an excellent choice for applications requiring easy demolding, particularly when dealing with intricate and complex part geometries. Urethane is well-known for its ability to maintain durability despite its flexibility, ensuring soft tooling longevity.
Another essential material in soft tooling is silicone rubber, known for its exceptional flexibility and heat resistance. Silicone rubber&#;s exceptional flexibility makes it an excellent choice for demolding complex shapes and parts with intricate undercuts. This property, combined with its ability to withstand high temperatures, makes silicone rubber ideal for molding applications requiring elevated curing or processing temperatures.
Hard ToolingAluminum is a lightweight metal known for its good thermal conductivity. It is particularly suitable for applications with moderate production volumes. Its lightweight nature contributes to ease of handling, while its thermal conductivity aids in efficient cooling during the molding process.
Steel, renowned for its high strength and durability, is preferred for projects with high production volumes. Its robust properties make it ideal for creating molds that must withstand extensive and prolonged use demands.
Stainless steel brings corrosion resistance to the table, making it an excellent choice for applications where exposure to moisture or corrosive environments is a concern. It combines durability with rust resistance, enhancing its longevity and suitability for various molding projects.
Titanium, known for its strength-to-weight ratio and corrosion resistance, is an advanced choice for hard tooling. It is particularly suitable for projects where a balance between strength and weight is critical
Plaster, while less common than metals, offers a cost-effective alternative in certain hard tooling scenarios. Plaster is a cost-effective material but is generally less durable compared to metals. Its affordability makes it an attractive choice for projects with budget constraints, especially when tool longevity is not critical.
Plaster is well-suited for low-volume production and prototyping. Its ease of use and mold-making capabilities make it a practical option for projects with more minor production requirements.
Applications of Rapid Tooling High-speed drillHere are the various applications of rapid tooling:
CNC MachiningRapid tooling in CNC machining involves the swift creation of tooling, such as molds or dies, to be used in the machining process. It allows for the quick production of prototypes and custom parts. Rapidly fabricating the necessary tools ensures a shorter lead time, enabling manufacturers to iterate designs rapidly.
CNC machines then use these tools to precisely cut and shape materials, allowing for the efficient production of intricate components. The adaptability of Rapid tooling in CNC machining proves beneficial for low-volume production runs where speed and customization are essential.
Die CastingIn die casting, Rapid tooling plays a pivotal role in creating molds used to produce complex and detailed parts. Rapidly fabricating these molds allows for accelerated production cycles, reducing the time required for tooling setup.
This speed is particularly crucial in the automotive and consumer electronics industries, where quick turnaround times are imperative. The rapid tooling process ensures that the molds are ready swiftly, facilitating the efficient casting of components with precision and detail.
Sheet Metal FabricationRapid tooling involves the prompt creation of tools, such as dies or punches, to shape and form metal sheets. This process is crucial for prototyping and custom enclosures. Rapid Tooling in sheet metal fabrication enables the fast production of protective casings for electronic devices and machinery.
Additionally, in the automotive industry, rapid tooling facilitates the swift creation of tools for forming vehicle panels and body components. The speed of tooling setup is essential in meeting production demands and achieving timely project milestones.
Considerations to Make Prototyping Molds CNC milling machine rough cuttingWhen venturing into prototyping molds, several vital considerations come into play to ensure effective and efficient mold design and production. These considerations include:
The choice of material for the mold is crucial. It should align with the specific requirements of the rapid prototype and the manufacturing process. Factors such as material properties, durability, and ease of machining must be considered.
Accurate size and smooth surface of the mold are paramount. The mold&#;s structure should be meticulously designed to meet the prototype&#;s specifications. Additionally, the design must facilitate high production efficiency and easy automation.
A balance between production efficiency and cost is essential. The mold design should optimize manufacturing processes, ensuring long life, low cost, and adherence to economic considerations.
The mold structure and parameters should align with the manufacturing process requirements. Rigidity, guidance, unloading mechanisms, and positioning methods must be carefully considered to enhance adaptability.
Wear parts in the mold should be designed for easy replacement. This consideration is crucial for maintaining the mold&#;s longevity and minimizing downtime during production.
ConclusionRapid tooling is a common method that manufacturers like to use. This technique allows manufacturers to speed up product development, save time and money compared to traditional tooling methods, and quickly test and validate product designs. Time to market is shortened, product quality and design are enhanced, and customer satisfaction rises. Rapid tooling allows manufacturers to iterate and alter the product design more quickly and efficiently.
At Zintilon, we offer our clients more than just assistance with custom design preparation for the rapid tooling process, which includes CAD software-generated 3D models. In addition, we provide tooling recommendations based on various specific project-specific factors, such as the customer&#;s soft or hard tooling preferences, budget, schedule, design complexity, materials, and tolerances. Contact us right now if you need quick tooling services!
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