Ethan Clarke
Prototyping is an essential step in the product development journey, allowing designers to test products before going to production. This process is especially important for plastic products, where demand for the final design may require subsequent investment in high-volume production tooling. There are several options for prototyping plastic parts, each with its own advantages and limitations. This includes 3D printing, CNC machining, injection moulding, and casting. When selecting a prototyping method, it is important to consider the type of prototype, the tests to be performed, speed, part tolerances, resolution, and cost.
| Characteristics | Values |
|---|---|
| Purpose | To test products before going to production |
| Types | Looks-like, works-like, functional, high-resolution, concept model, virtual |
| Testing Types | Engineering validation testing (EVT), design validation testing (DVT), production validation testing (PVT) |
| Manufacturing Techniques | 3D printing, CNC machining, injection moulding, blow moulding, rotational moulding |
| 3D Printing Techniques | FDM, SLA, SLS |
| CNC Machining Techniques | CNC milling, CNC turning, gear hobbing |
| Design | CAD model, 2D drawings |
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What You'll Learn
Computer-aided design (CAD)
CAD allows designers to create digital models that serve as visual representations of their future products. These models can be used to test out real-world conditions, loads, and constraints, creating a virtual prototype. The ability to create 3D models gives stakeholders additional perspectives on the product before construction begins. This aids in assessing design weaknesses early on and facilitates the conveying of expectations between designers, engineers, and clients.
CAD software simplifies the design process as changes can be made more easily and quickly in a computer environment. This boosts efficiency, making it simpler to create, test, and present a range of ideas. It also reduces the time and resources needed to produce physical prototypes, as issues can be addressed virtually before moving to the manufacturing stage.
Furthermore, CAD is compatible with 3D printing, which is often used for rapid plastic prototyping. CAD files can be directly imported into 3D printers, making the prototyping process faster and more cost-effective.
The future of CAD is also promising, with the integration of artificial intelligence expected to further enhance design efficiency, accuracy, and innovation. AI-driven tools can automate tasks, generate optimized designs, and predict potential issues, improving the overall quality and functionality of the final product.
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3D printing
The choice of material for 3D printing depends on the specific requirements of the prototype. For instance, ABS is a versatile and easily machinable material that can be injection-molded or used in 3D printing. It is also suitable for finishing techniques like sanding and texturing. However, 3D-printed ABS parts may lack the strength of injection-molded parts. Nylon, on the other hand, can be used in SLS 3D printing for a range of part types.
PLA is another option for 3D printing. It is made from renewable resources and is biodegradable, making it an environmentally conscious choice for prototypes that will be discarded after testing. While PLA is more breakable than other materials, it is suitable for medical devices and can mimic the qualities of the final product.
Other materials used in 3D printing include polycarbonate, which offers durability, and HDPE, which can create strong prototypes that replicate the qualities of injection-molded parts.
Compared to other prototyping methods, 3D printing provides the cheapest and fastest means of developing visual prototypes, which offer a final representation of the plastic part without requiring functionality. It is also useful for functional prototypes, allowing designers to test product designs before mass production.
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CNC machining
Compared to 3D printing, CNC machining offers tighter tolerances, better surface finishes, and reduced size limitations. It also has a wider range of materials available, resulting in prototypes with better structural integrity. However, 3D printing is generally faster and more cost-effective than CNC machining.
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Plastic injection moulding
To create a plastic prototype using injection moulding, the first step is to design a digital model using computer-assisted design (CAD). This visual representation of the future product helps manufacturers identify initial design challenges and determine the best production methods. The CAD file should include specific features to ensure the success of the injection moulding process, such as consistent wall thicknesses and the avoidance of sharp corners, undercuts, and other features that can lead to defects.
After the design is finalised, production engineers will determine the best materials and processes for creating the prototype. An initial prototype is often created using 3D printing, machining, or casting. This step involves close collaboration between the manufacturer and the client to ensure the prototype meets their needs.
The plastic injection mould is then created based on the design. Professional machinists craft the "tool" or "tooling mould" according to the blueprint, which includes the cavity, sprues, gates, and ejector systems. This step is typically the longest and most expensive part of the process, taking up to 20 weeks or more.
Finally, the prototype is created using the injection mould. This stage requires the expertise of the manufacturer to ensure the quality and consistency of the final prototype. Plastic injection moulding can support high-resolution prototyping, and steel injection moulds can achieve tighter tolerances than aluminium moulds.
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Testing
There are three types of testing during the plastic prototyping process:
- Engineering Validation Testing (EVT): This verifies that the engineering design meets functional requirements using the intended materials and manufacturing processes. It is about functionality.
- Design Validation Testing (DVT): This combines functionality testing with usability, reliability, and conformance. It confirms that the product fulfills its intended functionality, meets performance goals, and complies with user expectations and regulatory standards.
- Production Validation Testing (PVT): This assesses if the product is production-ready and can be manufactured consistently at high volume. It includes production testing and first article inspection (FAI).
The choice of prototyping method depends on the type of testing to be performed and other factors such as speed, part tolerances, resolution, and cost.
For example, CNC machining is commonly used for mid-stage functional prototypes as it offers fast production speeds and the same material options likely to be used in final production parts. However, it has less design freedom compared to 3D printing and can be more costly.
3D printing, on the other hand, is often used for initial prototypes as it is cost-effective, offers quick turnaround times, and has fewer design constraints. Selective Laser Sintering (SLS) 3D printing is a preferred option for engineers as it produces parts with excellent mechanical properties, such as stiffness, durability, and impact resistance.
High-resolution prototypes are ideal for pitching to stakeholders and evaluations as they deliver a near-final look and feel. This type of prototype can be effectively created using high-resolution 3D printing.
In summary, testing is a critical aspect of plastic product development, and the choice of prototyping method depends on the specific testing requirements and other considerations such as cost and production speed.
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Frequently asked questions
Plastic prototyping is the process of creating a preliminary version of a plastic product or part. It allows designers to test products before going to production.
Prototyping is an essential phase in the product development journey. It allows designers to determine whether their design works as intended before it reaches the end-user. It also helps to avoid costly design mistakes.
There are several types of plastic prototypes, including:
- Concept Model: A visual representation of the product or part.
- Functional Prototype: Includes key features, materials, and graphics of the final product.
- High-Resolution Prototype: Delivers a near-final look and feel, ideal for pitching to stakeholders.
There are several techniques available for plastic prototyping, including 3D printing, CNC machining, injection moulding, and casting. The best technique depends on the specific requirements of the project, such as cost, speed, resolution, and design flexibility.
