Prototyping

Prototyping

After the design stage of product development the next step is likely to be the creation of a prototype for assessment purposes. This process is likely to consist of a visual inspection & is likely to include a variety of tests to assess the products "fit for purpose" status. Tests are likely to include function, fit & form against the initial product specification & purpose. The processing facilities at Smithers Rapra are able to produce one off prototypes or can manufacture quality parts in relatively low numbers to the required specifications for "in use" test requirements.

Rapid Prototyping

There are different options for prototyping & the consultants at Smithers Rapra can advise you of the most appropriate. Methods available include:

SLA (Stereolithography)

SLA equipment uses 3D CAD data to construct models from a solidifying photosensitive epoxy resin using a high power UV laser. A number of different resins are available so that prototype models can be created as rigid, flexible or clear. The process can create highly complex parts fast & accurately & can then be finished as required, to provide visually pleasing components ready for fit, form & function testing. In addition the SLA process can be used as a master for silicon rubber or hard resin tooling.

SLS (Selective Laser Sintering)

The SLS process constructs prototype models from 3D CAD data via sintering of polyamide powder using a hot laser. The functional nature of SLS prototypes enables product validation testing & product certification.

Vacuum Casting

Vacuum casting of polyurethane resins from silicon rubber tooling offers many advantages including;

  • The fast production of representative parts following approval of a master model.
  • An ability to closely match a wide range of production materials to your specification including ABS, PP, PC, polyamide & elastomers.
  • The availability of a range of colours in addition to a transparent appearance. Other properties that can be accommodated include heat resistance & fire retardance.
  • Creation of intricate components including insert mouldings.
  • Over-moulding allowing plastics, elastomer & metal to be incorporated into one component.
  • Low volume production runs where conventional injection mould tooling would be prohibitively expensive.

Rim Casting

Large plastic components can be produced by rapid injection manufacture. This is a cold injection process, which does not require pre-heating of moulds or post curing of castings. This process typically produces less mould wear & one set of silicon tooling can yield up to 80 parts. For larger numbers, resin tooling can be used, making RIM an ideal solution for either rapid prototyping or low volume production. A wide range of production simulant materials are available.

Machining from rod & slab stock

Machining is usually employed when a design is tentative, of simple geometry & only a small number of prototypes are required.


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