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3D Rapid Prototyping Changing Manufacturing

Faster. better. cheaper Is the new mantra of today's manufacturing companies, which are using innovative methods to get their products to market faster, better and cheaper than ever before. Who would have thought these words would be used to describe manufacturing?

In the old days, manufacturing took time. "Time to market" was clearly a lengthy cycle in any industry because getting a product from concept stage to being available for purchase took time. Product development often had a difficult time making it out of the engineering department, based on such variables as initial approval, testing phases, budgeting, staffing allocations, manufacturing, shipping — the list goes on and on.

But today, that's all different. Thanks to an innovative process known as "3D rapid prototyping," time to market can be greatly reduced. And the strange thing is: the technology is nothing new. It has been around for nearly three decades.

Known as "additive manufacturing," 3D printing is used to fabricate models, prototypes and parts out of resin material. Using a CAD drawing, a part can be "printed" in a matter of hours.

Today's high-end 3D rapid-prototype printers have improved exponentially over the last decade. There are machines with better print quality and resolution, significantly higher run speeds, more material choices, properties and shades of color, and less of a footprint. It's possible to buy a 3D printer to sit on your desk — similar in size to a laser printer — for printing convenience at your fingertips.

So not only are 3D printers more capable, but the range and mechanical properties of 3D print materials are expanding. The result of all this is that advanced 3D printers are becoming a must-have fixture within every large product-development company, from the automotive sector to electronic goods and household appliances.

Manufacturers are able to cut out much of their secondary tooling processes, such as injection molding, resin tooling, mold making and soft tooling. And all of this will go into helping them shorten their time to market and reduce costs.

There's not a mechanical engineer on the face of the planet who wouldn't want to hold their product idea in their hands. To physically see it, to feel its material properties, and to test how it works. A design engineer could have a new product idea on Tuesday, design a CAD drawing of it on Wednesday morning, and print a 3D part to have in-hand for the sales department's customer meeting on Wednesday afternoon. Rapid prototyping virtually eliminates the need for preproduction tooling and speculative and costly manufacturing.

Engineers today are using 3D rapid prototyping much the same way the business world embraced "spell check" with word-processing documents. It's a step in the process that saves costly mistakes by enabling form, fit and function testing prior to manufacturing.

There's no end to the innovation that is taking place using 3D rapid prototyping, on a small and grand scale. According to The Wall Street Journal, Boeing plans to someday make an airplane wing without cutting or bending any metal, just using a giant 3D printer. General Electric is getting in on the act, too, for new technology in health care. From musical instruments to dental orthodontics and automotive parts, 3D printing is turning ideas into reality.

It's a fact that the U.S. is competing with other countries when it comes to manufacturing at reduced costs. 3D printing is but one tool to explore innovation and cost reduction, to determine if a product can be built stronger with less material, for example, or as a tool to check if a new design will function properly.

Businesses today compete with ideas in a global marketplace. In order to compete in this modern, "instant" world, ideas have to be very fast. What's your next-generation product? You'd better come up with it quickly and it needs to be better than your competition's.

One of our customers is a major luggage manufacturer. We built a prototype of handles and a new wheel design on a piece of luggage so it could be tested by a focus group for instant feedback, critical to the manufacturing process. Another customer, a world-renowned gaming-technology company, came up with a cover design that we prototyped for a casino machine that would use less plastic, saving millions of dollars in the process. For a major golf ball manufacturer, we prototyped four dozen balls, each with different dimple arrays, in a matter of two days. These balls were blown through a wind tunnel to see how they would react for speed and accuracy — something that would never have been possible before with traditional manufacturing processes.

The next major step in 3D printing is the home market. As the printers come down in price and the quality increases, more homes will be using 3D printing. Just think of the possibilities, if you break the control knob on your toaster, you just go to the manufacturers website and download the file for the knob. With the downloaded file, you simply send it to the printer and BANG you got a new knob.

When we were moving into our new offices, we needed some door stops to keep the doors open for the movers. Our team simply designed and printed door stops. Think about what that means to the current supply chain. In the future, door stops would not be inventoried at stores, a distributor would not be selling door stops and manufactures would not be making door stops. That's just one example. What about auto parts stores? In the future, when you need a part, the store will call it up on a computer and then print the part in the back room. This is truly "on-demand" manufacturing.

Also, in the future, 3D printers will be manufacturing human body parts. Right now 3D printers can jet human tissue through their print heads. With stem cell and DNA, replacement livers, kidneys, lungs, hearts etc. will be available if researchers can get past the government regulatory hurdles.

Three-dimensional rapid prototyping is revolutionizing the manufacturing floor. The future is here, and its "one-off," meaning it's possible to produce just one part or model cost effectively, versus having to produce thousands. When faced with the pace of rapid change, 3D printing is allowing more businesses to compete and take advantage of developing opportunities in their own backyards and around the world. It puts imagination and innovation back into the hands of more companies.

3D printing is only limited by the user's imagination. As the President said in his State of the Union address "3D printing will be the next industrial revolution".


Contact: R&D Technologies, Inc., 78 Romano Vineyard Way, Suite 114, North Kingstown, RI 02852 855-280-6477 E-Mail: acoutu@rnd-tech.com Web:
http://www.rnd-tech.com

 
 
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