CNC machining rapid prototyping: innovative development
Rapid prototyping technology, also known as rapid prototyping technology, Rapid Prototyping (RP technology for short). It can quickly manufacture new product samples, molds or models directly based on product design (CAD) data without preparing any molds, tools and fixtures. In short, rapid prototyping is a technology that specializes in making high-quality physical models with 3D design concepts. Rapid prototyping technology is another major revolution in the manufacturing industry after CNC technology.
The integration of CNC machining and rapid prototyping technology:
So what will be the effect of developing these two technological innovations together? CNC machining rapid prototyping technology has become the implementation point of this idea, allowing designers and engineers to quickly and accurately transform virtual designs into real prototypes. The technology combines the speed and agility of rapid prototyping with the complexity and accuracy of computer numerical control (CNC) machining.
When a company or enterprise develops a new product, it always needs to make a prototype of the designed part or system before funding a large number of production facilities or assembly lines. Prototyping will greatly shorten the enterprise processing cycle and reduce the cost of product development. In addition, prototyping is very useful in the process of design development and improvement, and is an important basis for production or engineering testing.
This guide will introduce all the knowledge about CNC machining rapid prototyping. Whether you are engaged in machining services or want to customize products, this article will be helpful to you.
1.What is rapid prototyping technology?
(1) Rapid prototyping technology
Rapid prototyping technology is integrated and developed on the basis of modern CAD/CAM technology, laser technology, computer numerical control technology, precision servo drive technology and new materials. It is the crystallization of multidisciplinary cross-technology.
(2) Rapid prototyping
Rapid prototyping is a technology that uses the CAD process of “holographic printer” to realize the automation of prototyping. Designers transform intangible ideas into tangible prototypes. When the design prototype meets the needs of customers and successfully completes the new product testing, it can be put into mass production. The prototyping process greatly shortens the processing cycle and reduces the cost of product development, which has a positive role in promoting enterprise product innovation and improving product competitiveness.
2.The basic principle of rapid prototyping
(1) The basic principle of RP
The basic principle of RP is to use three-dimensional technology to produce physical components. First, the 3D solid model data (STL file) is layered into layer model data (CLI file) in a certain direction. The rapid prototyping machine then uses specific materials to form a series of sheet-like entities with a small thickness based on these data.
(2) Subsequent production process
Then, by means of sintering, polymerization, bonding, etc., the layers are stacked together to form a new product sample, model or mold until the entire entity is created. After one layer of cross section is made, another layer is added on top of it, and this is repeated until the entire part is constructed layer by layer from bottom to top.
(3) The difference between rapid prototyping and 3D printing
Rapid prototyping is a type of additive layer manufacturing, which is similar to 3D printing, but rapid prototyping methods also include rapid processing procedures such as CNC machining, injection molding, stamping, and vacuum casting. Rapid prototyping can be used at any stage of the product development process, from creative improvement to final trial, to continuously improve design ideas.
3.Process characteristics of rapid prototyping technology:
RP uses a layer-by-layer material accumulation method to process solid models, also known as additive manufacturing (MIM) or layered manufacturing technology (LMT). This special processing method determines that it has the following technical characteristics that are completely different from traditional processing methods.
(1) High flexibility.
It can manufacture three-dimensional entities of any complex shape. The processing process does not require production preparation such as tools, molds or fixtures. For different part models, you only need to re-enter CAD data or adjust and set different process parameters. The production cost of a single piece is almost independent of the complexity and batch size of the product.
(2) Highly integrated CAD/CAM.
RP technology is directly driven by CAD models. The production of different parts does not require the design and use of special tools and fixtures, which can avoid cumbersome CAPP bottlenecks. The production process is completely digital, truly realizing seamless connection between CAD/CAM.
(3) Rapidity of the entire molding process.
From CAD design to prototype parts manufacturing, it usually only takes a few hours to dozens of hours to obtain high-precision and high-reduction products, which far exceeds the speed of traditional processing.
(4）High degree of automation.
The process is fully automatic, and no human intervention is required during the processing. After the parts are loaded, the equipment can work unattended.
4.Application direction of rapid prototyping technology
Since the 1980s, RP technology has developed rapidly and has been widely used in many fields such as automobiles, aerospace, medicine, and light industry. Its application directions are mainly in three aspects.
(1) Model.
RP technology has successfully solved the problem of “visible but intangible” three-dimensional modeling. Its greatest feature is that it can transform design ideas into product prototypes with certain structural functions at the fastest speed, making the design model from “visible (three-dimensional digital model) to “tangible” (solid model).
Therefore, one of the main functions of RP technology is to restore design ideas and quickly obtain conceptual products, focusing on the restoration and display effects of appearance. It is usually used for sales demonstrations and market promotion of new products, testing market reactions, thereby improving the market reaction speed of new product development and reducing development risks.
(2) Prototype.
The rapid prototype obtained by RP technology can fully evaluate the product’s assemblability and manufacturability. Due to the RP technology The high degree of integration of CAD/CAM can not only quickly restore the appearance of the product, but also quickly make product parts and structural components, so as to verify and analyze the structure and assembly of the product, quickly evaluate and test the product design, shorten the product development cycle, reduce development costs, and improve the ability to participate in market competition.
In addition, the product prototype can be obtained quickly. On this basis, the subsequent product mold design, production process, assembly process, and even the design of batch production tools and fixtures can be checked and evaluated to avoid production problems and huge losses caused by design defects after entering the batch production process, so that the product can be put on the market at the fastest speed, lowest cost and best quality.
(3) Unit manufacturing/small batch direct production.
Use the indirect molding method and combine various conversion technologies to convert RP prototypes into various rapid molds, such as silicone mold technology, RIM Technology, lost foam casting, etc. can easily realize the production of single or small batch products, meeting the development trend of fast product replacement and small batch.
5.Rapid prototyping process
It can be divided into two stages: early data processing (discrete) and subsequent physical realization (accumulation).
(1) Processing process
In the discrete process, the 3D CAD model of the part is decomposed along a certain direction to obtain a series of cross-sectional data, on which the motion trajectory of the forming head is obtained; in the accumulation process, the forming head processes each cross section of the part layer by layer under the control of the motion trajectory, and the layers of cross sections are repeatedly accumulated and connected to finally obtain the processed parts.
(2) Difference from traditional methods
Different from the subtractive principle of traditional cutting processing, this discrete growth-based forming technology obtains products in an additive way, which can be directly obtained from CAD The physical prototype (sample) of the product can be quickly produced by using the file.
(3) Functions and advantages
The produced physical prototype can quickly verify the product appearance and modeling parts assembly relationship or functional test, thus providing a measurable and touchable intuitive means, improving the human-computer communication in the design process and shortening the product development cycle.
6.Principles and functions of rapid prototyping models
According to the different functions of the prototype, there are three types of prototype models:
(1) Exploratory principle
This type of prototype is used in the demand analysis stage of development. The purpose is to clarify the user’s needs, determine the expected characteristics, and explore the feasibility of various solutions. It is mainly aimed at situations where the development goals are vague and both users and developers lack experience in the project. The user’s needs are clarified through the development of the prototype.
(2) Experimental prototype
This prototype is mainly used in the design stage. Assessment, whether the experimental plan is appropriate, whether it is feasible to operate. For a large system, if you are not sure about the design plan, you can use this prototype to confirm the correctness of the design plan.
(3) Evolutionary prototype
This prototype is mainly used for a system that quickly submits a prototype to the user. The prototype system either contains the framework of the system or the main functions of the system. After being recognized by the user, the prototype system will be continuously expanded and evolved into the final software system. It extends the idea of prototype to the entire process of software development.
7.Types of rapid prototyping
(1) Rapid 3D printing prototype
As a pioneer in the industry, different 3D printing technologies are suitable for different rapid prototyping stages. 3D printing services are generally used for model making in the following fields: rapid prototyping, mold making and industrial design, and then gradually used for direct manufacturing of certain products.
(2) Sheet metal rapid prototyping
Sheet metal processing is a subtractive manufacturing process that involves making parts from thin metal sheets by cutting, bending, folding, stamping and assembling. Sheet metal parts are usually highly precise and durable, so they are particularly favored by engineers and can be used in terminal applications such as chassis, brackets and chassis.
(3) CNC rapid prototyping
CNC rapid prototyping uses computerized equipment to make better designed models and fast turnaround prototypes. It is conducive to creating high-quality end-use materials.
CNC rapid prototyping can use different programs to create actual elements. Models developed using CNC rapid prototyping are easy to change or modify. Compared with other prototyping processes, CNC rapid prototyping is faster and can design the most complex elements in the simplest way.
(4) Rapid injection molding
With rapid injection molding, prototypes of injection molded parts can be created.
One of the most significant advantages of rapid injection molding prototyping is the creation of prototype models using different materials and colors.
CNC machines usually help to create rapid injection molding. The process also follows a method of transitioning to production, which can create thousands of parts.
(5) Vacuum rapid prototyping casting
This method allows the production of parts similar to mass production, with similar mechanical properties, wall thickness, color, and surface texture. It helps to cast resin and silicone models and helps to eliminate any potential bubbles.
8.New trends in CNC rapid prototyping
Looking forward, CNC machining is poised to continue to evolve and adapt to new challenges and innovations in rapid prototyping.
(1) Integration of artificial intelligence
Emerging trends include the integration of artificial intelligence and machine learning to achieve more efficient and precise machining processes. This advancement enables predictive maintenance, reduces downtime, and increases productivity.
(2) Adoption of advanced materials
A noteworthy trend in rapid CNC prototyping is the widespread adoption of advanced materials. Manufacturers are investigating a variety of materials beyond the traditional realms of metals and plastics, including composites and superalloys, which offer superior performance for specific applications. They exhibit properties similar to those of materials used in mass production, expanding the range of possibilities for material exploration during the prototyping phase.
(3) 3+2 and 5-axis milling
The shift to 3+2 and 5-axis CNC machining technology represents a major leap in machining capabilities, and this evolution has opened up new possibilities for creating unprecedented complex and precise prototypes. These advances have increased the accuracy and flexibility of rapid CNC prototyping, meeting the needs of industries with high-precision components and expanding market demand.
(4) Hybrid manufacturing
Hybrid production is a fusion of additive and subtractive methods that seamlessly integrates 3D printing and CNC machining in a single workflow. It provides a balanced solution for additive and subtractive production technologies that best utilizes the advantages of both technologies. Designers can now experience the design freedom brought by using additive strategies, while CNC machining ensures precision in important areas.
(5) Lightweight design
Manufacturers specialize in developing prototypes that meet specific requirements and prioritize weight performance, such as in industries such as automotive and aerospace. Reducing weight can improve gas efficiency and typical performance. CNC machining allows the creation of lightweight structures with complex geometries, which helps achieve the design trend of the most ideal power-to-weight ratio.
Summary:
These innovations not only enhance the capabilities of CNC machining, but also open up new possibilities for prototype development, making it an even more important tool in product design and testing.
9.Why is CNC machining the best choice for rapid prototyping?
CNC machining is widely regarded as the most efficient and cost-effective solution for rapid prototyping. CNC machining is the first choice for functional prototypes that require durability, precision and a finish close to the final product.
(1) Compared with other methods, CNC machining has obvious advantages in material strength and precision, which are critical for functional testing and design verification.
(2) In addition, CNC machines can process a wide range of materials from metals to plastics, giving designers the flexibility to choose the most appropriate material for their prototypes.
(3) The speed of CNC machining also plays a vital role in reducing time to market and enabling rapid iteration and modification based on test results or feedback.
10.Summary
So far, CNC machining rapid prototyping has undoubtedly simplified the way manufacturers or companies process and work. In conclusion, CNC machining has had a profound impact on the field of rapid prototyping, providing precision, efficiency and versatility. For companies that want to remain competitive in their respective markets, adopting CNC machining with TuoFa’s expertise is a strategic step towards success.