Industrial prototype

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Industrial prototype’s creation: services, sectors, products examples.

When we talk about industrial prototypes we refer to every technologies concerning rapid prototyping and rapid manufacturing which are suitable for the engineering of mechanical details in plastic or metal material.

Automotive, military, electronical devices and medical devices are the first sectors which were hit by additive revolution.

Considering the evolution of the machines, materials and know-how’s mechanical design, in constant transition towards 3D technology, are in continuous applications in new markets.

Our experience

To date we gained more than 20 years of experience in designing and producing industrial prototypes for manufacturing industry.

In 1998, when we bought the first stereolithography machinery, 10 years had passed since Chuck Hulls’ first patent.

In those years, rapid prototyping was a new addition. Many companies knew 3D mold technology, but just a few of them appreciated its benefits.

Through the years, technology developed mainly concerning materials and machineries. The process is the same: stratification through layers.

Technologies diversify themselves mainly for used materials and prototypes’ successive processing.

In our company we equipped ourselves with every technology for professional use because we exclusively work in B2B market.

3D mold prototype technologies for industrial use are:

industrial prototypes

Case histories and fields of applications

SLA stereolithography

Stereolithography is based on the polymerization of a liquid for a laser effect. Process starts with the creation of necessary support for the building of the place.

The transparent material Accura ClearVue comply with USP Class VI requirements for production of prototypes in contact with skin, food and drugs.

This technology is used a lot for aesthetic prototypes, for producing prototypes ABS-like and pre-series master from vacuum-sealed silicon mold.

It is used in every industrial sector when is necessary producing prototypes with easy paintable, smooth superficial finish.

Below you can find some examples of aesthetical prototypes in which most of the aesthetical parts are produced with stereolithography’s technology. The first case is a dental led lamp, the second is a washing machine in scale; these models are often used for showing the product to the final customer or setting up stands in fair or for preparing photo books useful for catalogue, waiting for the assembly of the product with plastics made by definitive mold.

DPL Stereolithography LCD

This technology is different from stereolithography for light source. The laser is replaced by a HD headlight. In this process the resin’s layer, hit by the headlight’s beam of light, make simultaneously harder every points of the same layer. It is very used in dental sector for investment and for contained work area.

SLS Sintering Laser Selection

Sintering Laser Selection used a laser for sintering PA powder. There isn’t any support because the place is supported by the same powder during the production. It can be also used loaded metal, glass or pottery powder to increase thermal and mechanical performances.

PA12 and PA12+30GF materials have USP class VI certification for the production of prototype in contact with skin, food and drugs.

This process is mainly used for the production of functional prototypes and it can be applied in every industrial sectors.

Right below there are one of the prototypes used for olives harvester. The customer needed an assembly test with electronic parts and any other internal part before passing to mold manufacturing for mass production.

olive harvester sintering prototype

FDM Fused Deposition Modelling

FDM literally means modelling with fused deposition and it is a three-dimensional modelling technology which used fibres of definitive material as ABS, PC, Ultem, PEEK.

ABS-M30i material is biocompatible in accordance with ISO 10993 and USP class VI rules for the production of prototypes in contact with skin, food and drugs.

This technology is also used in every industrial sector mainly when you need to manufacture prototypes for doing tests on definitive material.

Construction’s layers are visible to naked eye, so you need to sand the parts for having a smooth surface, but when you need a finished material, the more suitable choice is the one adopted by RADON.

stereolithography prototype

EBDM Electron Beam Melting

With this process you can produce lacking of vacuum and finished parts.

Currently it is successfully used in aeronautical, aerospace and biomedical sectors.

HP Multi Jet Fusion

Multi Jet Fusion technology is created by HP and it is based on a process called Thermal Inkjet.

The prototype is always manufactured in horizontal layers on layers made by materials and chemical agents necessaries for the outline of the part.

The superficial definition is quite smooth to the touch and prototypes can be used for usability, ergonomic, feasibility and trial tests.

Parts are printed in very thin layers until 80 micron, therefore prototypes present high density and low porosity in such a way to be waterproof and resistant to high temperature until 175°C as per technical sheet.

Even in this case the scope of application is mainly industrial in every sectors.

DMLS Direct Metal Laser Sintering

DMLS literally means direct sintering with metal powder; the laser liquefies powders for unite them layer by layer.

Materials mainly used in medical sector are titanium and cobalt chrome. This technology is fully used in production of medical and dental implantable prothesis.

This process, especially for cost reasons, is until now used in aerospace, automotive (mainly motorsport) and biomedical.

LCM Lithography-based Ceramic Manufacturing

It is an additive manufacturing technology developed on a photopolymerization DLP.

The system polymerizes a ceramic powder suspended in a photosensitive artificial resin. The final step plans a thermal passage in which the photopolymer matrix and the sintering are removed to obtain the final density of the part.

Vacuum Casting

With Vacuum Casting we refer to silicon mold replica.

Silicon mold replicas are excellent resources of Rapid Manufacturing for producing specifics in limited series using plastic material made with polyurethane.

It is possible producing specifics with firm, semi-firm and soft plastic.

This process is selected when is necessary to produce prototypes with better performances compared to any 3D mold process.

Given the good performances of the parts, in many cases in which the annual manufacturing of the products is limited, mold silicon replica become a real production process to assembly machinery to commercialize.

The more interested industrial sectors are: medical and customed electronical devices.

Below you can find a case history about a handle for endodermal massages.

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