Forside Sprøjtestøbning.Eksempler Aluminium.Støbning Hurtige.Prototyper FAQ

   
                            1.How should I select which Rapid Prototyping process to use?

The best way is to define the intended use of the prototype. As a general rule, Normally CNC prototype is a better choice.

2.What are the advantages of Rapid Prototyping?

Inventors and product development teams use rapid prototyping to help communicate their invention to customers, supervisors, manufacturers . Significant advantages of prototyping include reduction of project cost and risk. Generally, one or more prototypes are developed in a series of incremental and iterative steps. Each successive prototype is based on the previous product design stage's performance and it is a corrective process through which the past design defects or problems are corrected. The product is readied for production tooling when the prototype is refined as per requirements and meets all the design goals like manufacturability, robustness and functionality.

3.How does Reaction Injection Molding (RIM Molding) Work ?
Reaction Injection Molding (RIM) is the process by which molded polyurethane parts are made. In the process, 2 liquid components are mixed and injected into the mold where they chemically react and cure.
Polyurethane molded parts can be rigid and solid like an injection molded ABS or they can be a structural foam or elastomeric like rubber.
Two liquid reactants - polyisocyanate component and resin mixture - are held in separate temperature controlled feed tanks equipped with agitators. From these tanks, the polyol and isocyanate are fed through supply lines to metering units that precisely meter the reactants, as high pressure, to the mixhead. When injection begins and valves in the mixhead open, the liquid reactants enter a chamber in the mixhead at pressures between 1,500 and 3,000 psi where they are intensively mixed by high-velocity impingement. From the mix chamber, the liquid flows into the mold at approximately atmospheric pressure and undergoes an exothermic chemical reaction, forming the polyurethane polymer in the mold. Shot and cycle times vary, depending on the part size and the polyurethane system used. An average mold for an elastomeric part may be filled in one second or less and be ready for demolding in 30- 60 seconds. Special extended geltime polyurethane RIM systems allow the processor to fill very large molds using equipment originally designed for molds with smaller volumes.

4. What is STL format and how I can export from CAD package ?
An STL file is simply a mesh of triangles wrapped around a CAD model was defined by 3D systems in 1980s. STL, name is derived from rapid prototyping process, StereoLithography, also known as abbreviation of Standard Triangulation Language. This very simple format has become an industry standard for the Rapid Prototyping sector. Virtually all modern CAD systems now include STL or Rapid Prototyping output as a standard feature.

5.What is Rapid Prototyping ?
Rapid prototyping (RP) technology is used for building physical models and prototype parts straight from 3D CAD model, which is sectioned into many thin horizontal slices and data is passed to RP systems that join together liquid, powder and sheet materials to form complex parts layer by layer.

6.What's FDM?FDM also known as Fused Deposition Modeling is layered manufacturing process. FDM offers functional prototypes with ABS, and other materials. A thin bead of molten plastic is extruded through the computer controlled nozzle, which is deposited on a layer-by-layer basis to construct a prototype directly from 3D CAD data. The technology is commonly applied to form, fit and function analysis and concept visualisation. In addition, FDM can be used for pattern generation and rapid manufacturing.

7.What is 3d Printing ?
3d Printing is the less costly process of rapid prototyping which turns the 3D CAD data to quickly produce a three dimensional model for conceptual evaluation. Where an ordinary printer lays down a single 2D layer of ink on a sheet of paper, these printers add the extra dimension by printing layer after layer until you have a real, 3d object similar to your CAD model. Manufacturers report enormous productivity gains from using 3d printed parts.

8.What is SLA?
3d Printing is the less costly process of rapid prototyping which turns the 3D CAD data to quickly produce a three dimensional model for conceptual evaluation. Where an ordinary printer lays down a single 2D layer of ink on a sheet of paper, these printers add the extra dimension by printing layer after layer until you have a real, 3d object similar to your CAD model. Manufacturers report enormous productivity gains from using 3d printed parts.


9.How SLA Process works?
Stereolithography process produces plastic parts directly from 3D CAD model; by solidifying the surface of a liquid photo polymer layer by layer with the help of a laser beam. When the laser beam hits the liquid, it solidifies the resin. When a layer is fully traced, the elevator is then lowered in the vat. The self-adhesive property of the material causes the layer to stick with each other and in this way a 3d part is formed in multi-layers.

10.What is SLS?
SLS also known as "Selective Laser Sintering", primarily used to quickly produce three -dimensional prototypes, parts, direct mold inserts, tools, and lost wax casting patterns. SLS process provides durable, metal, plastic or rubber like prototypes directly from CAD model. These prototypes can be used as test parts for form, fit and function. SLS technology provides broad range of materials e.g. rigid thermoplastics, stainless steel, polystyrene, thermoplastic elastomers, cast form plastic for investment castings.

11. Can you make functional prototypes ?
It really depends upon the functionality of the product you want to achieve. We have various technologies available, to make functional parts e.g. FDM & SLS and CNC machining direct on industrial materials. Please check specifications and applications of different materials. Sometimes we machine prototypes from solid block of metal or plastic block to get the maximum strength when demanded.


12.What other services do you provide ?
We provide full range of Prototyping service, using our in-house facilities and network of partners. Some of services we provide 3D printing, SLA, SLS, FDM, CNC machining, Vacuum Casting, Investment casting, Sheet Metal parts and tooling, CAD/CAM service. Lately we started our new division of Architectural modeling. For more information please visit or Services section.

13.What tolerances can you hold?
Typical tolerances on our SLA models are about +/- 0.005". For parts over 5" we can hold around +/- 0.001" to 0.0015" per inch. Part geometry and build orientation can also have an effect on tolerances.

14.What do you mean by "High Resolution" Stereolithography?
High Resolution is a special mode on a Viper si2 SLA system. The diameter of the laser beam is decreased from about 0.010" to about 0.003"-0.004" and parts are built at a layer thickness that has been shaved from 0.004" to 0.002". The effective area for this mode is 5"x5". Parts best suited for high resolution are small with intricate detail and/or extremely small features. High Resolution parts are more expensive than their Normal Resolution counterpart.

15.What is RTV tooling?
A. RTV means Room Temperature Vulcanization. It refers to a rubber material that will completely cure at room temperature. By encapsulating your part in silicone, we can create a rubber mold that will allow us to make a number of copies of the part using, in most cases, a polyurethane.

16.Why would I want a urethane casting?
Urethane casting can make sense when your project requires a high number of models or when the properties of the SLA materials may not meet the requirements of your particular application.

17.How many parts can you produce from one silicone mold?
A. The answer to this question is highly dependent on part geometry and choice of material, but typically you can expect a single rubber mold to yield about 25 parts.

18.What is Stereolithography (SLA)?
Stereolithography is a layer additive rapid prototyping process that creates a solid object from a 3D computer model by using a computer-controlled laser to draw cross-sections of the object in succession onto the surface of a liquid photopolymer.

19. What are the main applications of Rapid Prototyping?
Although there is a big listing of prototyping applications. This technology is maturing rapidly specially in automotive, medical, toys building, packaging, aerospace, electrical, scientific applications and so on.
Few examples here :
a) Imagine there is a major exhibition next week and your new product is still in development stage, How to get the part urgently? just send us your CAD file rest is up to us to meet your deadline.
b) Why to take a risk of getting unrealistic quotes from your suppliers by sending 2d drawings, when you can send inexpensive 3d physical part which will not only help to save money at the end but also helps to open new options to manufacture the part or tooling.
c) Manufacturers who need parts in small quantities where tooling or production cost is not justified.
d) Sometimes it is difficult for the designers or toolmakers to visualize or find out the problems in the drawings, by having the 3d part in their hands, helps them to figure out the problem and redesign it if required before investing on actual tooling.
e) Helps the medical field in many different ways specially for reconstructive surgery by making 3d models created from CT scan of the patient's body parts.
f) Quickly making master model for vacuum casting to produce small quantity of Poly Urethane parts.
g) If you are a student, scientist, teacher and you need to make a part for your next project or class demonstration, what to do? Rapid prototyping is the quick answer for you.
h) Building my new home but like to see how the design will look like in real life.
i) To make some Artistic or unique design for example statue, jewelry, special type of toy even some part is broken of your home appliance which is not easily available in the market.
j) Any spare parts or auto part hard to find in the market.
k) Tooling inserts for plastic injection moulding direct in steel able to produce thousands of parts.

20. When is RTV Molding useful for rapid prototyping?
RTV is very helpful when you need a spec-like material for multiple sets, in a short timeframe, for less than a traditional tool would cost.

21.How Does RTV Work?
The RTV mold is created from a master pattern, typically an RP model. The pattern is used to create a silicone rubber mold. The silicone is poured around the pattern to produce a core and cavity of a mold. The RP model is then removed, leaving a negative image into which polyurethane is cast. These molds can produce up to 20 parts per mold, and they can be made as family or multi-cavity molds.


22.RTV Urethane Molds
RTV (Room Temperature Vulcanization) silicone molding is a well-recognized rapid tooling method for producing small quantities of production-like prototypes of plastic injection molded parts. Short mold lead times are coupled with exceptional detail and surface finish. Complex parts with undercuts can be produced using this process. RTV molding is very cost effective at low quantities while maintaining good accuracy and excellent detail. Prototype parts can be color matched and textured with a variety of material characteristics. Durometers range from very soft foams or rubbers through very rigid nylon-like materials. Some functional testing can be performed.
Use RTV Silicone Molds when your project requires short lead times, low volumes, production-like characteristics, and fine detail and surface finish.
Understanding Urethane Molding
Urethane molding is a process where a master pattern, typically created by stereolithography, is used to cast a silicone mold that can then be injected with various urethane materials.
Step-by-step Process
1. Create and prepare master pattern. Usually the best choice for master pattern is a SLA model. However, existing parts or machined parts can also be used with success. If an SLA model is used, it can be polished for a smooth finish or textured for a custom look. The finish of the pattern will transfer to the mold and cast urethane pieces.
2. Create the silicone mold. The mold parting line and vent and fill holes are determined based upon the part geometry. There are various methods for creating a parting line; two of the methods used by Bastech are clay for a two pour mold or tape for a single-pour mold. To create a two-part mold, the parting line is clayed and the part is enclosed in a box. Silicone is poured around the model to create its negative. The part is then flipped, the clay is removed and the second half of the mold is poured. Once the silicone has cured, the master is removed and the mold is cleaned and prepared for injection.
3. Inject and pressurize mold. Urethane material is mixed and/or colorized and injected into the mold through fill holes using low-pressure pneumatic gun injection method. The mold is placed into a pressure pot to compress air bubbles that may have been trapped during injection.
4. Remove parts from mold. After the allotted cure time has passed, the molds are removed from the pressure pot, opened, and the part is then carefully removed.
5. Post-finish urethane reproductions. Gates and flashing are removed from urethane parts. Straightening is sometimes required. The parts may also be painted, polished, or functionally assembled. Threaded inserts, if not added during molding, can be added at this time.
23.Stereolithography
Stereolithography is an additive fabrication process utilizing a vat of liquid UV-curable photopolymer "resin" and a UV laser to build parts a layer at a time. On each layer, the laser beam traces a part cross-section pattern on the surface of the liquid resin. Exposure to the UV laser light cures, or, solidifies the pattern traced on the resin and adheres it to the layer below.
After a pattern has been traced, the SLA's elevator platform descends by a single layer thickness, typically 0.05 mm to 0.15 mm (0.002" to 0.006"). Then, a resin-filled blade sweeps across the part cross section, re-coating it with fresh material. On this new liquid surface the subsequent layer pattern is traced, adhering to the previous layer. A complete 3-D part is formed by this process. After building, parts are cleaned of excess resin by immersion in a chemical bath and then cured in a UV oven.
Stereolithography requires the use of support structures to attach the part to the elevator platform and to prevent certain geometry from not only deflecting due to gravity, but to also accurately hold the 2-D cross sections in place such that they resist lateral pressure from the re-coater blade. Supports are generated automatically during the preparation of 3-D CAD models for use on the stereolithography machine, although they may be manipulated manually. Supports must be removed from the finished product manually; this is not true for all rapid prototyping technologies.

24. Low-Volume Injection Molds & Parts
Ready-to-shoot injection molds in 2-3 weeks!
APC´s Partner provides ready-to-shoot Aluminum tools (QC7) for customers who need production parts in short order. For our customers who cannot wait 12-16 weeks for traditional or offshore tooling to be made, APC´s Partner offers Low-Volume Injection Mold Tooling and Parts.
In contrast to our Rapid Injection Molding offering, Low-Volume Injection Mold Tooling & Parts has no geometry limits on part dimensions and allows any commercially available material and surface finish.
With press sizes ranging from 20 tons to 1,000+ tons, APC´s Partner can meet your injection needs;

25.PolyJet technology
Polyjet C This process is similar to stereolithography in that parts are made with a photosensitive resin. The difference is in how the resin is applied and cured to build the part.
PolyJet technology uses a jetting head to accurately build each layer at 16 microns (0.0006 inches) thick, which is about 1/5 that of stereolithography layers. The jetting head slides back and forth along the X-axis, jetting tiny droplets of UV resin onto the build tray. Immediately after building each layer UV bulbs alongside the jetting head cure and harden each layer subsequently.
Two different materials are used for building: one material is used for the actual model, while a second, gel-like UV resin is used for support. Each material is simultaneously jetted and cured layer by layer. When the model is completed, support material is easily removed with pressurized water.
Because of the super thin layer thickness, the resulting parts are very accurate and have a very smooth surface finish.

26.High Speed Machining for CNC Rapid Prototypes
Our high speed CNC machining operation allows us to facilitate short lead times and competitive pricing on precision CNC rapid prototypes and masters, and also for short-run needs, hybrid molds, and presentation models. We operate the latest software and machines manufactured by Fadal and HAAS, including part beds up to 84" x 30, which are equipped with 4th axis motion. Complex feature and contoured surface programming is handled with the latest version of Mastercam, a package that programs quickly and runs NC check to verify each setup and cutter path is accurate.

27.Versatile Rapid Prototypes
Stereolithography (SLA®) provides accurate models and patterns in record time. Concept models, masters and patterns are created in record time using stereolithography, the most accurate and precise rapid prototyping technology available. Complete in-house finishing
capability for production-like prototypes ensures your model and patterns are delivered on time, ready for immediate application.
SLA models and patterns can be produced in a matter of hours from any popular CAD system. Starting with CAD geometry, IGES or STL data, Solid Concepts' engineers will guide your most demanding project through every step of the process to guarantee timely delivery.
In-house developed software and special finishing techniques make it possible for Solid Concepts to provide the highest level of quality at competitive prices.
Because of their accuracy and ability to reproduce fine details, SLA models are ideal for use as concept models, form and fit studies, and as master patterns for a variety of molding techniques. Options for finishing include color-matched painting, texturing and pad printing, to give your model a "production quality" look and feel.
SLA Standard
SLA Standard C Built in 0.007" layer thicknesses, our SLA Standard process is suitable for prototypes and master patterns that need to be built quickly and economically.
SLA Premium
SLA Premium C Built in 0.005" layer thicknesses, our SLA Premium process provides xcellent detail, requires less post finishing work, and is suitable for quality prototypes and master patterns.
HDSL C High Definition Stereolithography
If you need the ultimate resolution available in SLA processes today,take a look at our HDSL service.
QuickCast®
Solid Concepts has developed a next generation QuickCast custom build style/algorithm and material to produce light rigid investment casting patterns. These patterns are 10 to 35% lighter then those built with other materials and standard QuickCast build style/material
combination assures accuracy and optimum casting yield.

28.Reaction Injection Molding (RIM):

Low Quantity Injection Molding For Life Sciences Industry
The Reaction Injection Molding (RIM) process economically produces low quantity injection molded parts for the Life Sciences industry. Medium to large enclosures and housings can be produced in low quantities from low-cost tooling. Designing for the RIM process is easier than designing injection molded parts because the RIM process allows much more design freedom.
The RIM process is relatively new and perhaps the least understood, most under utilized of the low-pressure processes for plastic parts. Recent developments in resins have allowed this high-value process to compete with injection molding. Thin wall parts that meet UL flame requirements can be produced with faster cycle times. Plastics experts call RIM "the low-pressure process that comes closest to duplicating injection molding's attributes. It has impressive large-part, small quantity and low initial investment capabilities."
OEM's in the Life Sciences industry are using RIM instead of injection molding, vacuum forming, pressure forming, structural foam, sheet metal, or metal casting. RIMs lower cost tooling allows them to get their products to market faster and to change them more .
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