Why You May Want to Outsource Your Rapid Prototyping Projects

Whether you want to create high or low fidelity prototypes, you need to follow a procedure that gives you a complete picture of how the product will look and perform. Companies that offer rapid prototyping service for physical parts often want a fast process, and that is why they use a variety of techniques. However, there comes a time when such companies need to outsource such services. For example, if you do not have enough time to work on all the prototypes, the only viable option is to find an expert who understands how to do it better.

The Pros of Outsourcing Rapid Prototyping Projects

One of the most significant advantages of outsourcing rapid prototyping projects is the fast turnaround time. Sometimes, clients want their products to be fabricated fast, and that means that you will need an extra pair of hands to meet their demands. With outsourcing, you can divide the project into smaller parts and have them distributed to different experts. In addition to that, outsourcing ensures that you serve several clients simultaneously, regardless of the size of the projects.

More Creative Control

You will also enjoy outsourcing rapid prototype projects because it gives you more creative control. You will have more control of the way the projects are conducted because you have a team that is backing you up. For example, you can ask for their recommendations on various techniques and see how much creativity they add to your projects. If you are short of ideas, all you need to do is to ask the team to come up with ways of creating the prototypes, and you will end up with the perfect plan.

If you are looking for ways to expand your business, outsourcing rapid prototyping projects may be the best way to go. If your clients learn that you have enough resources to handle every stage of their projects, they will be willing to give you more business. Once they know that they can count on you to deliver the projects on time, they will not hesitate to contact you reach time they have a new project, and that is how your company grows. You will also notice that such clients will recommend you to their contacts so that you have enough work to keep you busy throughout the year.

The Cons of Outsourcing Rapid Prototyping Projects

Most outsourced rapid prototyping projects lead to low printing volumes because of lack of a breakthrough, especially with new clients. However, you can overcome this challenge through aggressive marketing, such as the use of word of mouth. In addition to that, outsourcing can lead to the inadequacy of resources. For example, you may have to spend time and money training your recruits before you can trust them with the projects.

In a nutshell, outsourcing rapid prototyping projects can help you to grow your business and provide fast services. However, you need to plan effectively and find the right experts to work with to avoid problems with your clients. Work with a team of experienced experts to get high-quality prototypes.

Different Kinds of Automotive Prototypes

An automotive prototype is used to show if a product can be made, the most suitable material for it, and its production equipment. It is a vital part of the process since it helps developers make new automotive products of good quality that attract stakeholders to invest and form a good customer base in the market. The automotive prototype plays a vital role in the designing and processing of cars. In this write-up, we look at the types of automotive prototypes.

Types of Automotive Prototypes

The safety of a car, its performance, and its development are dependent on the prototype. They include:

1. Design Validation Prototypes

Initially, designs are created virtually using computer-aided designs (CAD). A prototype is made to create a physical object using cost-effective techniques like plastic injection molding. It helps manufacturers achieve clarity, visualize the concept, and share it with investors.

2. Pre-Development Prototypes

They are more refined and smooth. They are made once a design is validated, and a stakeholder has shown interest in the product. At this stage (mule stage), the prototype is used to decide whether the item can be used and correct the design errors. Donor cars are usually provided, and their body is taken off. The product is then placed on the automobiles to check if it fits and reacts with the other parts.

3. Manufacturing Process Prototypes

Techniques such as CNC machining, metal stamping, and forming are used to determine the best method of developing the parts. The automotive prototypes easily spot any problems that may arise during production. There are many manufacturing processes, and the most cost-effective one is chosen.

4. Customer Testing Prototypes

They are used for customer testing during the production process. Dialog between the developer and consumer is crucial. Feedback from customers who plan to use cars is essential as it helps engineers pitch their ideas. They can also correct issues pointed out by the potential users and select the best material to be used for the final product.

5. Safety Testing Prototypes

The test carried out is known as Failure Mode Effect Analysis (FMEA). The prototypes are taken through different situations to see how they behave in those respective situations. They are also placed in harsh conditions to show if they can withstand heat, water, etc. without causing any problems that may stop consumers from using the product.

6. Manufacturing Validation Build Prototypes

These prototypes are made last, as this is the final stage of preparation. They are very expensive and take a lot of time to develop them. They help in estimating how long the manufacturing process will take. The method of producing an object for market use is different from that of creating a functional prototype. It is a complicated process that needs high precision. The actual equipment and machines make the prototypes, and the final touches are done.

Bottom Line

Automotive prototyping is a vital process of the development of cars. Multiple automotive prototypes are always developed when a new product is being created. They are often refined to get the best design and methods of processing.

Things to Consider When Buying 3D Printers

There are different makes and models of 3D printers to consider. For instance, there are a consumer and industrial 3D printers. You can find some that handle materials such as ceramics and metals. No matter your intended use of 3D printing, you need to get the right machine.

Selecting Professional 3D Printers

Intended Application

Your end-use determines the functional requirements of the printer. Do you want to make prototypes? Is a great visual appearance or smooth surface important for you? Does durability matter? What about material properties? Maybe you want to create functional products that support the operations of your business, such as fixtures and jigs. These choices will influence the type of creality 3D printer you choose.

Materials

You should note that there is a link between the 3D printer and the material it uses. For instance, when you purchase certain 3D printers, your material options become limited. For instance, SLA printers use thermoset resins, whereas FDM/FFF printers use thermoplastics.

Even if the printers are using the same manufacturing technology, each is compatible with a certain set of materials. For instance, lower-end FFF printers can only use prototyping materials such as PLA. On the other hand, engineering-grade materials such as composites or nylon need adequate process control and higher processing temperatures. That means you can only use them with industrial-grade 3D printers.

Therefore, you should consider the materials you have access to before choosing a printer. Some printers provide dual extrusion capability. Therefore, you can print in different colors. Remember that some printers use only materials from the manufacturer. It is advisable to consider printers that can use a wide range of materials.

Resolution

The minimum layer height and the smallest part size the printer can produce determine its resolution. For instance, nozzle diameter of 0.4 mm means that your printer cannot make details smaller than 0.4 mm. If you want parts with fine details, you should consider choosing laser 3D printers. That is because the spot size of these printers ranges from 0.1 to 0.2 mm.

The layer height is quite important as 3D printers manufacture parts by adding layers. However, a small layer height does not mean you will get better results. Most applications require default height. Although a higher resolution is important, it is not a guarantee of high-quality. If you are manufacturing large parts, you should use a large layer height and nozzle. That is because fine details are not critical, and when you increase the layer height, you can considerably reduce build time.

Software

Since 3D printing involves the use of computers, the type of software you choose is quite important. Every printer comes with software or slicer for preparing CAD files. You should note that the capabilities of the slicer vary. For instance, some can allow automation and preset parameters.

You can also find 3D printing systems with tools that make monitoring, connectivity, and management easy. For instance, they can support Wi-Fi integration, sensors, and cameras. With such tools, you can print parts from anywhere as long as you have an internet connection. This is quite advantageous when managing multiple machines remotely.

Aluminum injection mold vs Steel Injection Mold- Which is better?

The old-age battle when it comes to injection molds will definitely be steel or aluminum injection mold. The debate is fierce and many manufacturing companies take one side over the other. However, what do you think? Are aluminum injection molds making better than steel molds? If you are confused, we might help you make a decision.

We will compare both molds by using several factors. We hope to find a clear winner at the end of the day. Even if we don’t, we hope things will be much clearer to you by then.

Aluminum Injection Mold or Steel Mold?

How much does each mold cost?

To produce either mold, you will have to spend some cash. However, which one requires less spending? When you consider the initial spending needed to be carried, there’s no doubt that the aluminum injection molds clearly have an edge here.

While this is true, it’s also important to look at the bigger picture. The final cost of each mold might change drastically when other factors are considered. For example, the estimated lifespan of each mold might require you to spend more on the aluminum injection mold.

However, on average, the aluminum injection mold is less likely to cost more than steel.

Which mold is suitable for low volumes?

Again here, the aluminum injection mold just comes out on top. Low-volume runs are always better suited to aluminum injection molds and this is not going to change anytime soon. The reasons for this range from lower costs to the production of more pieces.

I’d recommend that you make sure that you choose a material that matches the volume you intend to use. Some might just be better with the steel mold.

Which mold is suitable for high volumes?

The steel mold comes out on top here. Unlike low volumes, the steel mold is better suited for high volumes and more runs.

The advantage of using a steel mold here is that you get a final product that is sturdy and can last for a long time. All you have to do is to ensure that you carry out proper maintenance.

Which mold cools and heats up faster?

It’s obvious who wins this round. The aluminum just has the perfect material for heating and cooling off quicker. The steel mold is always going to struggle when it comes to this category. The faster your material can cool off, the faster the cycle time is going to be.

When you use aluminum injection molds, you should be able to have a much faster output than with steel molds.

Final Verdict

So what do we think? We think the aluminum injection molds are overall the best type of mold. However, there are circumstances where the steel mold might be better.

However, when considering the facts and the big picture, it’s almost impossible to see how the steel molds come out on top.

So if you are considering what type of mold to use, we would recommend that you use aluminum injection molds for your business. It’s just the better option if we are being completely honest.

Various Processes of Cleaning You May Want to Know

Laser cleaning refers to a unique process of removing different contaminants like oil and oxides via laser ablation. The process allows for the selective removal of various contaminants with just little impact on the actual substrate. As you may know, industrial cleaning is pretty much involving. So what is a laser cleaner and how many types of cleaning processes are there on the market?

The actual removal of oil from different metal parts is known to be annoying. The processes involve chemical solvents that are rather specific to every material that needs to be removed. This implies it may be prudent to replace an old part instead of giving it a new look. While it may be slightly blurry what a laser machine actually does, there are legitimate answers to some of your questions as outlined in this article.

 Background Information

The importance of laser cleaning is tremendously growing, especially in applications like the removal of debris from various semiconductors. The same applies to art conservation.

And with the rise in the introduction of a protocol that proposes reduction on the environmental as well as health grounds when it comes to the uses of solvents like CFCs which are usually utilized in cleaning, it is highly expected that additional available industrial elements of laser cleaning can emerge in the future. Let us look at the basics of dry laser cleaning.

Dry Laser Cleaning

There are various types of laser cleaning processes. Dry laser cleaning is just one of them. It is often used in various industries as researched in academia where generally it is founded on a thermal energy transfer found between the contaminant as well as the substrate.

Typically, it will end up, resulting in the rapid thermal expansion of different components that offer some force to get rid of the particles. One common problem encountered in the technique is the reduced cleaning efficacy since the decomposing products build-up, thereby masking the surface that needs cleaning.

 Wet Steam Cleaning

Wet laser cleaning is a process that utilizes a liquid layer which absorbs the wavelength in use. Laser irradiation may rapidly heat the liquid, thereby forcing the particles found on the surface to evaporate. As a result, some particles will be forced from the surface. Alternatively, a workpiece can be kept in a humid atmosphere, resulting in condensed water.

Steam laser cleaning utilizes a think liquid layer, highly condensed on the surface of the substrate. The liquid layer will then be superheated, causing the nucleation of different bubbles in the liquid’s solid surface.

As a result, high pressure will be released. The pressure may be strong enough to yank out particles from the surface. Generally, steam cleaning needs lower laser influences, especially for the removal of particles.

Fiber Laser Cleaning

Just like there are several cleaning processes on the market, there is more than one type of laser cleaning process. We have highlighted the most important ones in this blog post, hoping that they will have an impact on the type of business you are running.

 

Brief Review of the Main Injection Mold Types

The manufacturing world is evolving, and plastic is the primary material used to make items from synthetic body parts to automotive. With the need to create essential components and ensure optimal performance, manufacturers are now choosing to use plastic injection mold. Thus, to suit multiple industry needs, there are several types of injection mold available, offering extraordinary features and benefits. And an application’s specifications can determine the right molding process for a specified part. Below are the common injection mold types.

  1. Family Mold

A family mold refers to a single mold base with two or more cavities that allow for the intense production of different parts. These parts can be produced simultaneously.

The shut-offs can also be used in isolating production to the selected cavities. Also, to get impeccable results, the parts need to be similar in resin, volumes, and shape.

Automation can be necessary for separating the pieces, particularly after production. And if the cost of the mold is anything to go by, then a family mold is your best option.

  1. Hot Runner Molds

Hot runner molds use tools set at a temperature-controlled setting to condense the runner scrap in the cycle. This can help improve various cycle times.  A sprue system can be used in determining the molding cycle. Hot runner molds need a temperature controlling for a press to run in.

A controller is then used to match the manifold found in the mold. That said, you should note that the hot runner molds have a high maintenance cost. But, the return on investment is always invaluable, especially for applications that need expensive engineering grade resins.

  1. Cold Runner Molds

A cold runner mold is a system that operates at a cold temperature without any additional heating systems. Usually, the sprue, runner, as well as the gate, are cooled alongside the molten material and additional plastic ejected.

The plastic molten can quickly be recovered and then recycled if it created from a thermoplastic resin.

  1. Single Cavity

Single cavity mold produces a single part for every cycle. The initial investment is lower compared to other forms of molds. For that reason, it is often used for more economical production rates.

Unlike the multi-cavity mold, a single mold is useful in ensuring that production is always running even if there happens to be a breakdown in a single mold. Single cavity mold is flexible in controlling injection molding processes.

  1. Two-plate injection Mold

Two-plate injection mold comprises a single parting plane. The mold will then split into two major halves at a parting place while the runner system has to be located on the same parting plane. The system is generally used for parts that are gated around their edge.

Take-Home

There you have it from revered experts in this field. Selecting the right type of injection mold highly depends on the geometry, production volume, quality, and design tool. The highlighted plastic molding processes come with unique features and added advantages, making every style ideal for different applications.

 

3D printing technology: Beneficial uses in the manufacturing sector

3D printing’s manufacturing applications may not include printing atoms, but even that goal isn’t unreachable. The technology had evolved significantly since the 1980s when its idea was initially conceived.

Indeed, its rapid development is not unconnected to the rapid growth of certain markets today. You probably wonder how valuable 3D printing could be to your manufacturing effort. Here are some practical applications of 3D technology for a manufacturer.

Prototyping

Before you start ordering expensive titanium and wood treatment reagent, how about prototyping with 3D technology instead? The value of 3D printing to prototyping across all industries can’t be overstated. Its proper name is “rapid prototyping.”

The name is because of how fast it makes the task of getting your idea in physical shape. You don’t need expensive working models when a 3D printed model can demonstrate your idea to investors. Rapid prototyping isn’t a new idea to the manufacturing scene; it’s already happening and becoming increasingly rapid.

Low-Demand Manufacturing

There’s no doubt that 3D printing is too slow for manufacturing large-volume products with massive demands. However, low-volume products with low demand are fair game with a 3D printer. It’s a valuable technology to test run new product lines with uncertain market demand.

You’ll find such type of fabrication mostly with high-value goods that command low demand. It satisfies the need for customization of look and function without raising the price sky-high. Technological advancements in 3D technology also mean that high-volume product fabrication may not be a pipe dream for the future.

Parts and Components

Sometimes, the crank of your power tool breaks down, and you have to wait for a week until a new one arrives. 3D printing saves you the stress of the wait and allows you to continue the job within a few minutes. Start your printer, load up the crank design, print it, replace the old crank with it, and continue your work.

3D technology simplifies the problems of industrial holdups by providing an easy alternative for replacement parts. You can quickly make valuable repairs to your tools and equipment without spending too much money. Many small-scale manufacturers also innovate fast by using the technique to reduce the development costs for their products.

It’s not just small businesses that benefit from 3D technology either because even Porsche is using it. Massive companies like Airbus can replace complex plane interior components by simply printing the exact dimensions. In 2018, Ford won major honors for its lightweight assembly lift assist that was 50% cheaper than its counterpart using FDM.

Lightweight Products

Weight is one of the great enemies of manufacturers and consumers worldwide. Replacing some heavy parts of your product with lighter 3D printed parts is a new hobby for manufacturers. With the right 3D printed casing and material components, you can make your final product extremely lightweight.

Final Thought

As 3D technology continues to evolve, its status as the future of manufacturing also continues to increase. You are certain to benefit from the capabilities of printing atoms once that evolution is complete.

 

Brief Analysis Of The Types Of CNC Machine Services

CNC machining services from China play a critical role in the creation of numerous intricate elements needed in multiple industries. Although mass production can work for different applications, other sectors need tailored parts for specific areas and use. The possibility and capability to design these parts accurately using a computer have driven several companies to seek the input of CNC machining for their success. Everything, including the medical industry and transportation, relies on these machining parts. Thanks to the development of computers, the process has a way of allowing for intricate tailored designs in production.

Types Of CNC Machines

There are several types of CNC Machines on the market. They all come in handy in the manufacturing processes. Generally, they are six. But in this blog post, we put our focus on the 3 best and leading in the sector.

  1. CNC Router Machine

This is one of the most common pieces of machinery you may come across in the industry, whether as a learner or devoted user. The machine is built in a way that it can precisely operate the CNC technology without the input of a human being.

Routers are used for producing slightly larger dimensions coupled with an in-built design that helps to cut wood and sheet metal. The routers are also mostly found in the 3 axes coordinate set up. This design allows the machine to cut different profiles and pocket 3-dimensional machining.

Other than that, there are CNC routers with the 4,5, and 6 axes. These ones come with an additional rotary which is used in rotating the tool located at the workpiece of the device. The machine is suitable for cutting intricate shapes.

CNC Machining Services

  1. CNC Lathes Machine

A lathe is utilized in developing a precise yet conical part. The machine is prominent for making good use of turning centres when cutting a tool and shaving off excess elements of materials as it rotates. 

  1. CNC Electric Discharge Machines

ED machining (EDM) comes with elements that can be used to make certain types of shapes inside a particular material by utilizing an electrical release. The material is typically dispensed from a workpiece using a progression of electrical releases from two anodes. The mentioned anodes are then isolated using a dielectric liquid. The liquid often receives a viable electric voltage.

Final Thoughts- Industries That Use CNC Machining Services

Precision is a tenet that matters in most industries, including medical, aerospace, as well as petrochemical. Component failure in the stated market can prove to be risky in life. This explains why different businesses in the sectors mentioned need the highest levels of accuracy to be successful in their endeavours. CNC machining can help achieve the required standard of precision in order to save lives.

Besides, manufacturers in different industrial sectors have CNC machines used to create needed products. The machines use various techniques to operate. Some industries can choose to use CNC machining to fulfil orders online.

That’s it from us. As a prospect business professional, you need to educate yourself with the basics of operating CNC machines, including why and where they may be needed.

 

What is the anodizing process?

My be, at one time or another, you have come across metal parts with a beautiful aesthetic design and finish. Most of these parts are made from the metal aluminum because aluminum parts possess enhanced mechanical attributes. The process of anodizing aluminum entails creating a layer of oxide on the metal’s surface, a process leaves the metal surface with an exceptional finish, as well as increasing the adhesive potential of the metal. The procedure of anodizing aluminum also enables glue and specific paint primers to be easily applied to the parts, while also increasing corrosion resistance.

How anodization of aluminum is done

Even though almost all metals can be anodized, the most popular choice of metal for the process is aluminum. Anodizing aluminum involves an electrochemical process that leaves a layer of oxide film on the metal by dipping it in an electrolyte solution. In scientific terms, that aluminum is the “anode.”

The next step is to pass an electric current through the anode and the cathode. But, the best choice for the cathode is flattened aluminum bars. The current passes through the electrolyte, usually sulphuric acid, on its way between the anode and cathode.

Types of anodizing

There most famous examples of anodize include:

  • Chromic Acid Anodize (CAA)

This process generates the thinnest coat of oxide on the aluminum surface. Done correctly, the chromic acid anodizing can offer protection as good as the other more advanced anodizing techniques. The result is a gray-colored surface that is capable of absorbing less color in a dye process. Aluminum parts made by this process are used in aerospace components, precision machined parts and welded assemblies.

  • Boric-Sulfuric Acid Anodize (BSAA)

The BSAA offers a fantastic option to chromic acid anodize; this is mostly as a result of the rising concern over human safety/ health concerns, environmental safety concerns, and lastly, the associated costs of CAA. The BSAA process is mainly applied for the sake of paint adhesion and corrosion protection. Aluminum parts that are treated using the Boric-Sulfuric Acid Anodize process are used in precision machined components, as a paint base, and in aerospace components.

  • Sulfuric Acid Anodize (SAA)

This is the most common process for anodizing aluminum. This option is mostly applied where abrasion resistance and hardness are required. As a result of the process, the sulphuric acid forms a porous film just before sealing. SAA is utilized by adding colored dye, resulting in brilliantly colored surfaces. Popular colors include black, gold, and coyote brown, and urban grey. Parts derived from this process are used in computer and electronic components, mechanical hardware, optical components, and hydraulic valves.

  • Hard anodize (hard coat)

This process also involves a sulphuric acid electrolyte. It results in a metal surface that is denser and thicker compared to parts obtained from SAA. It is best for metal components that will be used in extreme wear environments. Extremely high abrasion resistance is required. Hardcoat is also applied where electrical insulation is needed. The parts from hard coating feature improved wear resistance, harder finishes than tool steel, and can be dyed black. Valves, cams, swivel joints, and pistons use hard coat-processed aluminum.

Conclusion

Note, anodizing aluminum results in durable, hard, and abrasion-resistant parts that can be used in consumer goods, electronics, aircraft parts, and sporting gear. It helps metal parts outlast raw metal parts while also providing thermal insulation.

Nylon Injection Molding for Absolute Beginners

Nylon is a widely used synthetic thermoplastic polymer. It is a flexible, durable, and very versatile material that is commonly used in injection molding applications. Nylon is often used as an affordable alternative for other materials such as latex, rubber, and silk.

Items made from nylon plastic (PA) tend to have features such as:

  • High melting point
  • Excellent tensile strength
  • Resistant to abrasions and chemicals
  • Low friction

Thanks to its specific chemical composition, nylon has a very high melting point. That makes it a top alternative for metal components exposed to high temperatures. The most common uses are in car engines and other machinery where there is high-friction. The fact that it doesn’t heat that easy when in a high-friction situation makes it unique. Same as other thermoplastic materials, once it reaches its melting point, it turns to liquid instead of burning. That means it can be easily melted, remolded, or even recycled.

Another great trait of nylon plastic is that it easily combines with other materials. That way, we can improve much of its qualities and make the produced items applicable to other uses.

One such example is filling it with fiberglass. That will reinforce its tensile strength on account of its flexibility that will decrease. Plus, it will make it more brittle.

Different Variants of the Nylon Material

There are different variants of nylon, but not all are popular and commonly used as Nylon 6, Nylon 66, Nylon 6/66, and Nylon 6/6.

The numbers reveal the number of carbon atoms found among the amine and the acid groups. The single digits like 6 reveal that the polymer is made from a single monomer, which is in conjunction with itself. That makes it a homopolymer. The two digits, like 66, reveal that the polymer is made from several other monomers in relation to each other. That makes them comonomers.

Then there is the slash that means the polymer consists of several groups of comonomers that are in relation to each other. The term used to describe that is a copolymer.

Nylon Plastics in Everyday Life

Thanks to its excellent versatility, nylon is used for all sorts of products, such as:

  • Fishing line
  • Reinforcement for rubber.
  • Threads and ropes
  • Clothing and fabric
  • And a lot more

Thanks to plastic injection molding, nylon is also cast into plastic bearings, bushings, gears, and other types of mechanical equipment such as engines.

To Conclude

Nylon is no easy material to work with, especially if you are a beginner and don’t have much experience under your belt. It is a temperamental type of material, that if not treated right, can lead to low efficiencies and high scrap.

You can get consistent quality of products via injection molding by proper material handling, meticulously following all the procedures, tool design, and concentrated processing.

That’s the only path to excellent nylon molding and efficient production of excellent products. Any other approach is merely an improvisation, waste of time, money, and resources.