PCB Prototyping can be defined as the process of constructing physical objects automatically by making use of ‘solid freeform fabrication’. The initial techniques Prototyping came into being in late 1980s. They were then used for producing prototype parts and models. Today you will see these used in much wider applications. For instance- manufacture of quality parts. This technology is used by certain sculptors for producing complex shapes in order to display them in ‘fine arts exhibitions’.

Origin: Rapid Prototyping has taken virtual designs through ‘animation modeling software’ or ‘computer aided design (CAD)’. The next phase becomes the transformation of the thin and horizontal cross sections. Each cross-section then gets created in the physical space. This process goes on till the model gets completed. It is better known as WYSIWYG process. Let’s understand this process in detail.

WYSIWYG: WYSIWYG as the abbreviation for ‘What You See Is What You Get’. It is used in ‘computing’ for describing a system wherein content looks similar to final product at the time of editing. It is generally used in word processors. However, this use is in the form of HTML (Web) authoring. Flip Wilson was the comedian who made this phrase popular. His character ‘Geraldine’ used to say this very often to give an excuse against her idiosyncratic behavior.

This expression came to be applied later to computer-based applications as practicality in technology arrived. At times, it is phonetically spelt as ‘Wizzywig’ or ‘Wizywig’. It has also been used as a brand name for a ‘lighting design tool’ utilized in theatre industry to pre-visualize the shows and 3D CAD.

The process further : The additional fabrication causes the machine to read data from CAD drawing. After that, consecutive layers of powder, sheet material, or liquid are laid down. Vary Similarly, you can build up a model from a chain of cross sections. Such layers, corresponding to CAD model’s virtual cross section, are then fused automatically or joined together for creating the ultimate shape. The basic advantage of additive fabrication goes to state that any geometric feature or shape can be created through this.

The CAD software and machines are interfaced by the ‘standard data interface’ in the ‘STL file format’. The function of STL file is approximating the shape of an assembly or a part by making use of triangular facets. Surfaces of higher quality are produced by smaller facets.

The word ‘rapid’ can be used relatively. Depending on the models sometimes the construction of these models could take a few hours all the way up to a few days. This depends on the technique used, along with the complexity and size of the model. The additive systems take less time. They can produce models within some hours. Some techniques such as ‘solid freedom fabrication’ make use of two materials for construction of parts. The 1st material is known as ‘part material’ and the 2nd one as ‘support material’. The removal of support material takes place by heat. It might also be dissolved with water or any other solvent. When it comes to manufacture of plastic products, that too in large quantities, injection molding proves to be a cheaper alternative. 

 
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Prototyping is a process by which a working model or prototype is developed to test the various design ideas, features, concepts, use, functionality and performance. The Manufacturer can get almost immedite feedback from the consumer or end user. The technology of rapid prototyping is quite revolutionary and innovative and has found widespread applications in nearly all types of industries. The prototypes can be developed on the basis of past design and its performance and necessary modifications can be made to refine the final product as per the requirements. Rapid Prototyping has manifold advantages like reduction of process cost, time and risks, conceptualizing of the actual product, delivery of high quality product, better communications and so on.

As it is with all the technologies, there are some disadvantages as well associated with rapid prototyping like communication gaps, high expectations of the users which are not fulfilled and so on. Really when you look at it, the benefits outweight all of the disadvantages. Lots of different processes and techniques are available with rapid prototyping.

Rapid Prototyping Technologies: The numerous rapid prototyping technologies may include the various types like additive, formative or subtractive. Initially, rapid prototyping technologies involved only additive processes. The major difference between the various additive technologies is the method in which layers are built for creating parts. Some rapid prototyping technologies melt or soften materials for producing the Layers (FDM, SLS), whereas other technologies lay down liquid material called thermosets and these are later cured by different methods.

The various rapid prototyping technologies are SLA or Stereolithography, SLS or Selective Laser Sintering, LOM or Laminated Object Manufacturing, SGC or Solid Ground Curing, LENS or Laser Engineered Net Shaping, FDM or Fused Deposition Modeling, 3DP or Three Dimensional Printing, Inkjet, EBM or Electron Beam Melting and miscellaneous non-commercialized technologies.

SLA or Steroelithography: The Invention Prototype technology of SLA or stereolithography provides with the greatest accuracy and gives the best possible surface finish among all the rapid prototyping technologies. This technology uses liquid photopolymer resin that has the property of solidifying on contact with the correct color light. The most commonly used photopolymer materials need UV light, but resins that work in visible light are also used.

SLS or Selective Laser Sintering: SLS or Selective Laser Sintering rapid prototyping technology uses metallic powders or thermoplastics. This technology is quite similar to stereolithography. The finishing time is reduced as the undercuts and overhangs are given support by the solid bed of powder. The surface finishes are not as good as stereolithography. It requires no final curing like SLA, but the object is porous as it is sintered. The mechanical characteristics of the object can be improved by infiltrating the object with some other material as required by the application. Ceramic Tools and Metal Object and the direct fabrication of these things is one area where this method is used.

 
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Rapid prototyping is a revolutionary and powerful technology with wide range of applications. The process of Rapid Prototyping involves quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance. The user is able to give immediate feedback regarding the prototype and its performance. Rapid prototyping is essential part of the process of system designing and it is believed to be quite beneficial as far as reduction of project cost and risk are concerned.

Rapid prototyping is known by many terms as per the technologies involved, like SFF or solid freeform fabrication, FF or freeform fabrication, digital fabrication, AFF or automated freeform fabrication, 3D printing, solid imaging, layer-based manufacturing, laser prototyping and additive manufacturing.

History of Rapid Prototyping :

Sixties: The first rapid prototyping techniques became accessible in the later eighties and they were used for production of prototype and model parts. The history of rapid prototyping can be traced to the late sixties, when an engineering professor, Herbert Voelcker, questioned himself about the possibilities of doing interesting things with the computer controlled and automatic machine tools.  These machine tools had just started to appear on the factory floors then. Voelcker was trying to find a way in which the automated machine tools could be programmed by using the output of a design program of a computer.

Seventies: Voelcker developed the basic tools of mathematics that clearly describe the three dimensional aspects and resulted in the earliest theories of algorithmic and mathematical theories for solid modeling. These theories form the basis of modern computer programs that are used for designing almost all things mechanical, ranging from the smallest toy car to the tallest skyscraper.  Volecker’s theories changed the designing methods in the seventies, but, the old methods for designing were still very much in use. What happened in the older days included a machinist and most likely a machine tool that was controlled by a computer. The metal hunk was cut away and the needed part remained as per requirements.

Eighties: However, in 1987, Carl Deckard, a researcher form the University of Texas, came up with a good revolutionary idea. He pioneered the layer based manufacturing, wherein he thought of building up the model layer by layer. He printed 3D models by utilizing laser light for fusing metal powder in solid prototypes, single layer at a time.   Deckard developed this idea into a technique called “Selective Laser Sintering”. The results of this technique were extremely promising. The history of Invention Prototype is quite new and recent. Hence, rapid prototyping can be used in a wide variety of applications and thus has become extremely popular and has grown by leaps and bounds.

Voelcker’s and Deckard’s stunning findings, innovations and researches have given extreme impetus to this significant new industry known as rapid prototyping or free form fabrication. It has revolutionized the designing and manufacturing processes.

Though, there are many references of people pioneering the rapid prototyping technology, the industry gives recognition to Charles Hull for the patent of Apparatus for Production of 3D Objects by Stereolithography. Charles Hull is recognized by the industry as the father of rapid prototyping.

Present-day Rapid Prototyping: Today, the computer engineer has to simply sketch the ideas on the computer screen with the help of a design program that is computer aided. The nice thing about CAD or computer aided design is that you can make the exact adjustments you need in a 3D design environment.

 
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