Newsletter July 2009

In this issue:

• Prototyping Makes a Great First Impression

• Prototyping Solutions

• Bright Future for Digital Manufacturing

Prototyping Makes a Great First Impression

A prototype of a fan made with ABS, a strong production-grade thermoplastic used across many industries.

Do you want to make a great first impression but are unsure which technology to choose? Read about the advantages and disadvantages of the most popular technologies below. For detailed information on cost, material properties, turn time and accuracy; see the comparison chart at the bottom.

1. Virtual Prototyping
Virtual prototyping is a simulation of the part being designed created by 3D CAD software. It is ideal for early conceptualization because it allows parts to be designed, revised, virtually fitted together and tested using finite element analysis. The drawback is that it is entirely virtual, so going directly to high volume production from this point is very risky.
 

2. Fused deposition modeling (FDM)
FDM is an additive fabrication process that melts solid thermoplastic and extrudes it through nozzles not much thicker than a human hair (minimum extrusion of approximately 0.01 inch). It is a relatively inexpensive process which produces durable, functional prototypes as well as low-volume production parts. It is more accurate and stronger than other additive technologies and can produce very complex (even unmanufacturable) geometries. Sometimes it suffers from stair-stepped surface finishes (although this can be resolved with post-processing via Ready Part) and only works with a range of materials.

3. Stereolithography Apparatus (SLA)
SLA is an additive fabrication process that uses a laser to cure layers of photopolymer resin. The process is suitable for making concept models to support presentations or trade shows. It is a relatively inexpensive way to make a single part and produces a good surface finish. The drawback is that it only works with a very limited range of proprietary resins and produces a fragile end product whose dimensional stability suffers over time.

4. Selective Laser Sintering (SLS)
SLS uses a laser to fuse powdered material. As is the case with SLA, SLS is suitable for making initial prototypes for demonstration purposes and is relatively inexpensive. SLS produces more durable parts than SLA, making it a good choice to test form and fit. Unfortunately, the parts produced are still too weak to be used for testing. As with other technologies, SLS works with a limited range of materials and the resulting parts have a rough finish.

5. Photo-polymer Jetting (PolyJet)
PolyJet is similar to SLA, using computer controlled UV light to cure layers of photopolymer. As is the case with SLA, PolyJet is used primarily as a concept modeling process. PolyJet offers the same advantages as SLA, but typically costs less and produces a finer surface finish. When compared to SLA, PolyJet is more limited in the size of parts that can be created.

6. CNC Machining
CNC machining uses traditional manufacturing equipment to cut parts from a solid block of material. The process is useful for demonstration parts through low volume production. It is as fast as the additive fabrication processes and produces parts comparable to injection molding. Unfortunately due to price, it is generally not well suited for production quantities in excess of hundreds of parts and is not a green alternative due to wasted material. Further, CNC cannot easily produce complex parts with internal cavities and undercuts.  

Download Prototyping Comparisons Chart >

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Prototyping Solutions

Our prototyping solutions comparison chart will help you compare FDM, SLA, SLS and CNC material properties, cost, finish and production time. Find our which technology is best for your project.

Download Prototyping Solutions: A Comparison Guide PDF >

We know that decisions made during prototyping phase have an impact, sometimes dramatic, on the cost to manufacture your product. That’s why we don’t just produce quality plastic parts. We strive to create satisfied customers. You can rely on us for our expertise, instant, accurate estimates and on-time delivery.

Our on demand global network is just one click away to help you with your rapid prototyping needs. Get started.

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Bright Future for Digital Manufacturing

In this economy everyone is striving to get their product to market faster. With digital manufacturing from RedEye, now you can speed your products to market faster than ever before.

Just a few years ago, our services were primarily used for prototyping. Wohlers Report 2009, a 250-page analysis of the newest developments and trends in additive manufacturing (AM) notes a bright future for digital manufacturing. And, just as Wohlers Report 2009 explains, the use of AM for direct part production (aka: direct digital manufacturing) has grown to become the second most popular application of our services.

According to the new report, AM is being used for custom and replacement part manufacturing, limited-edition products, short-run production, and in some instances, full production (coined digital manufacturing). New materials and increased awareness of digital manufacturing has likely led to the change in manufacturing processes.

"Additive manufacturing is causing some companies and individuals to rethink the way products are developed and brought to market," says Terry Wohlers, principal author of the report.

"A new type of manufacturer is emerging that is not operating from a traditional manufacturing facility."

Whether you’re designing one, prototyping ten or need one thousand production parts – trust RedEye On Demand.

Get Your Copy of Wohlers Report 2009 >

Start Production Online with a FREE Estimate

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