Rapid Prototyping

CAD Model of Steering Knuckle

Rapid Prototyping (RP) is defined as a group of techniques used to quickly fabricate a scale model of a part or assembly using three-dimensional computer aided design (CAD) data. What is commonly considered to be the first RP technique, Stereolithography, was developed by 3D Systems of Valencia, CA, USA. The company was founded in 1986, and, since then, a number of different RP techniques have become available.

Rapid Prototyping has also been referred to as solid free-form manufacturing, computer automated manufacturing, and layered manufacturing. RP has obvious use as a vehicle for visualization. In addition, RP models can be used for testing, such as when an airfoil shape is put into a wind tunnel. RP models can be used to create male models for tooling, such as silicone rubber molds and investment castings. In some cases, the RP part can be the final part, but typically the RP material is not strong or accurate enough. When the RP material is suitable, highly convoluted shapes (including parts nested within parts) can be produced because of the nature of RP.

There is a multitude of RP methodologies appropriate for verifying CAD/CAM files prior to production of military parts. Those RP techniques that are commercially viable include Stereolithography (SLA), Selective Laser Sintering (SLS®), and Laminated Object Manufacturing (LOM™) techniques.