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RAPID PROTOTYPING METHODS
The most common types of rapid prototyping methods are additive technologies,
meaning that the model is built by adding material layer by layer. By contrast,
subtractive prototyping methods create a model by removing material, typically by
means of standard machining methods such as milling, grinding and drilling.
A rapid prototype originates with a computer model. Typically, this model is
fabricated using computer-aided design (CAD). A prototyping machine reads the
computer data and slices it into different layers of thin (~.005 in.) cross-sectional
planes. The machine then builds the prototype by adding material layer by layer.
Rapid Prototyping uses a standard data interface, implemented as the STL file
format, to translate from the CAD software to the 3D prototyping machine. Typically,
Rapid Prototyping systems can produce 3D models within a few hours. Yet, this can
vary widely, depending on the type of machine being used and the size and number
of models being produced
Below is a list of common rapid prototyping/additive manufacturing methods.
lStereolithography (SLA): This method is used to make plastic models. It
uses an ultraviolet laser beam to harden liquid photopolymer resin.
lSelective laser sintering (SLS): This method uses a high-power laser to
fuse the material into a 3-D object. It can be used with a variety of materials,
including plastic, metal and ceramic powders.
lElectron beam melting: This technique, developed and trademarked by
the Swedish company Arcam, uses an electron beam to build a model layer
by layer from metallic powder. The process takes place in a vacuum at a
high temperature.
lRapid injection moulding: This is a variation of traditional injection
moulding, but produces plastic prototypes faster and cheaper.
lDirect metal laser sintering (DMLS): use of any alloy metal to build up
model.
Prototyping is used to evaluate and test the design, ergonomics, safety, functionality
and other aspects

of a device. Choosing the right prototyping process can enable companies to notice
design errors and other issues that could later cause significant problems, thereby
saving both money and time.
Rapid prototyping can be used at almost every step in product development
process, like
Conceptualization: concept models, marketing mockups Initial Design: form, fit, and
function testing, visualization Detail Design: testing, test fixtures, assembly testing,
fit, form and function testing. Production: tooling, mockups for process planning

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