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Rapid Prototyping Process
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RP involves a number of steps that move from the virtual CAD description to the physical resultant part. Different products will involve RP in different ways and to different degrees. Small, relatively simple products may only make use of RP for visualization models, while larger, more complex products with greater engineering content may involve RP during numerous stages and iterations throughout the development process. Furthermore, early stages of the product development process may only require rough parts, with RP being used because of the speed at which they can be fabricated. At later stages of the process, parts may require careful cleaning and post processing (including sanding, surface preparation and painting) before they are used, with RP being useful here because of the complexity of form that can be created without having to consider tooling.

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Stage 1: CAD

All RP parts must start from a software model that fully describes the external geometry. This can involve the use of almost any professional CAD solid modelling software, but the output must be a 3D solid or surface representation. Reverse engineering equipment (e.g., laser scanning) can also be used to create this representation.

Stage 2: Conversion to STL

Nearly every AM machine accepts the STL file format, which has become a de facto standard, and nearly every CAD system can output such a file format. This file describes the external closed surfaces of the original CAD model and forms the basis for calculation of the slices.

Stage 3: Transfer to RP Machine and STL File Manipulation

The STL file describing the part must be transferred to the RP machine. Here, there may be some general manipulation of the file so that it is the correct size, position, and orientation for building.

Stage 4: Machine Setup

The RP machine must be properly set up prior to the build process. Such settings would relate to the build parameters like the material constraints, energy source, layer thickness, timings, etc.

Stage 5: Build

Building the part is mainly an automated process and the machine can largely carry on without supervision. Only superficial monitoring of the machine needs to take place at this time to ensure no errors have taken place like running out of material, power or software glitches, etc.

Stage 6: Removal

Once the RP machine has completed the build, the parts must be removed. This may require interaction with the machine, which may have safety interlocks to ensure for example that the operating temperatures are sufficiently low or that there are no actively moving parts.

Stage 7: Post processing

Once removed from the machine, parts may require an amount of additional cleaning up before they are ready for use. Parts may be weak at this stage or they may have supporting features that must be removed. This therefore often requires time and careful, experienced manual manipulation.

Stage 8: Application

Parts may now be ready to be used. However, they may also require additional treatment before they are acceptable for use. For example, they may require priming and painting to give an acceptable surface texture and finish. Treatments may be laborious and lengthy if the finishing requirements are very demanding.

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