3D rapid prototyping
They’re certainly not as fast or versatile as Star Trek’s “replicators,” which, in a few seconds, could whip up anything from a glass of Romulan wine to a spare part for a warp drive. But a new generation of rapid prototyping (RP) machines is bringing science fiction closer to reality.
The machines take three-dimensional computer designs and turn them into objects made in a variety of materials, including wax, metal, plastic and even chocolate, meticulously building them layer by layer. To show off its new Titan rapid prototyping machine at a Cincinnati trade show last month, Eden Prairie, Minn.-based Stratasys had it turn out polycarbonate golf balls and invited attendees to give them a whack. The balls not only had enough zing to travel 250 yards but they were durable enough to dent several clubs. (Z. Shan; et al, p469-475)
“I see a day when companies will buy these in the 100s, instead of dozens,” says Scott Crump, founder and CEO of Stratasys. “They’ll be like printers. When they get down to $5,000, you’ll see them in homes.” The idea behind rapid prototyping, which has been around for about 13 years, is to “print” objects. A device much like a printer head meticulously adds layer after layer of a substance to create a 3D object. The most sophisticated RP machines work to tolerances of plus/minus 1/1000th of an inch per inch. The breadth of customers and range of rapid prototyping applications is growing as prices drop and more engineers use 3D computer-aided design programs.
Using traditional hand sculpting or machining methods, it can take days or weeks to make models, prototypes and master patterns for tooling and production. But RP machines can make them in hours, generating them from a designer’s three-dimensional computer-aided design. Some machines can turn out items two to three feet in diameter.
Ford, Boeing, DaimlerChrysler, Sunbeam, Black & Decker, Disney, Mattel, Toro, Polaris and scores of other companies use rapid prototyping machines to build actual size or scale models of everything from engine blocks and toaster parts to airplanes and the latest action figure dolls. (Kotouczek, p22) They go to mass production once they have the prototypes finalized. RP technology is employed to make limited production runs of needed parts, too, at a cost of a few dollars to several hundred dollars. In fact, NASA is considering the using Stratasys machines to make spare parts in space. It’s very expensive to carry spare parts into space- Rapid Prototyping Association. They’re looking at how they can manufacture parts when they’re up there. And they’re looking at materials on the moon to see if it’s possible to use them to produce parts.
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