Well-equipped CNC machine shops almost always use prototyping as a primary part of their production technique. It’s the process by which models of parts and components are made for closer inspection by the client and their design team. Those prototypes then get tested in real-world situations to determine whether they need re-machined or not.
Thus, the quality of a prototype is essential to precision manufacturing, especially for high accuracy industries such as aerospace, automotive, and medical. So, what’s the difference between traditional prototyping and rapid prototyping? The answer is rather significant.
Why is prototyping important for CNC machining?
As the confirmation and customization phase, prototyping is essential to manufacturing an exact component. It provides the production team with enough time for unexpected adjustments, and it verifies the strengths and/or weaknesses of the design as well. Since clients want to see and touch their components before mass production, this phase isn’t usually skipped.
Moreover, precision prototyping helps clients demonstrate their new product designs to other team members while discussing investment and development opportunities in the meantime. For example, vendors and potential partners typically wish to test various concepts before adopting them. Fast and accurate prototyping helps them do that while keeping the door open for changes to the design.
Depending on the needs of the client, different types of prototyping can be used. High-performance CNC machinists may even be able to help evaluate the initial blueprints before testing begins. However, it’s important to understand how traditional prototyping and rapid prototyping differ.
What is traditional prototyping?
Traditional prototyping is what has been used for decades to design, develop, and create accurately scaled models of various products. This method requires years of training and can take many hours to complete. Using tools such as pen, paper, and CAD software, skilled machinists are able to fabricate temporary representations of complex parts and components with only basic blueprints.
This somewhat difficult, albeit simplified, way of doing things allows machinists to build whole or partial models for quick or careful examination. It may or may not function as intended, but the primary components will be present to evaluate and customize. Meanwhile, extra mock-ups can also be made using different materials and machining techniques, including some that must be completed by hand.
DID YOU KNOW: Traditional prototypes are better for some projects than rapid prototypes, and your machining team will consider the difference.
What is rapid prototyping?
Rapid prototyping (RP) uses a completely different process to create 3D models of parts and components. First, the material gets carefully milled on a high-tech CNC machine or created using industry-leading software with 3D printing stereolithography capabilities. As the more complex and precise option of the two, RP techniques can fabricate nearly identical mock-ups as opposed to simplified forms.
In fact, this technique is even used to help visualize digitally rendered products before they’re sent out for production. RP is also ideal for testing the strengths and weaknesses of a part prior to mass manufacturing, although each prototype is slightly more expensive than the former option. Either way, it helps save money on the back-end as ideas and design concepts get explored more quickly.
DID YOU KNOW: Efficient RP lets teams move beyond merely visualizing their part to understand the innate properties of their design more easily.
What are the benefits of rapid prototyping?
Rapid prototyping has many advantages. For one, it provides an enhanced ability to perform 3D additive manufacturing on scaled models of parts and/or assemblies. Plus, it does so without involving process planning or tooling, thereby helping to cut costs and reduce waste throughout every step. Here are 4 more benefits of RP to consider:
#1. Paper-Free and Eco-Friendly
RP uses state-of-the-art technologies to whip up 3D part models from a CAD file on a 3D printing machine. That means no wasteful paper trails during the development process, a thinner margin for error, and a much smaller carbon footprint.
#2. Enhanced Material Compatibility
The materials used in rapid prototyping are more versatile than simple traditional prototyping. That’s because RP can involve anything from ABS and PVC to TPE and PLA. Commonly, materials such as silicone, resin, nylon, and stainless steel are also used.
#3. Better Speed Control
Experts can command their parts with more ease when they use RP software and machinery. Highly complex geometries which would be nearly impossible on traditional prototyping machines are much easier to make as well.
#4. Improved Machining Precision
Using 3D printing, additive manufacturing, and/or foam modeling can help demonstrate certain properties while requiring a lot less manpower. That, in turn, means lower production costs and improved precision on all finished parts.
Whether you choose regular, traditional prototyping or the more high-tech version, it’s important to understand what you’re getting into. Remember, a prototype is supposed to get used as a learning tool for visualization, experimentation, and customization. It is not the end result, although RP parts may appear eerily similar to the finished product.
How to choose between traditional and rapid prototyping
Casting production can be extremely costly if you choose the wrong prototyping and tooling methods. The early stages of CNC machining often require many changes as well, meaning cost-effective processing techniques must be used throughout to save time and money. What used to take several weeks with traditional prototyping now takes only a few hours with RP.
In general, rapid prototyping is best for projects that require several design modifications or component adjustments. It’s also more ideal for complex geometries and tight deadlines. As a matter of fact, that’s precisely why industries such as automotive, aerospace, medical, marine, and bio-engineering trust it so much.
The thing about traditional prototyping is that it serves many purposes and could be the wisest choice for several projects. However, only rapid prototyping offers such high levels of precision at such swift speeds. Between the skilled machinists, intuitive design teams, state-of-the-art software, and versatile material compatibilities, RP marks the future of fast and efficient CNC machining.