In some cases, the prototype is called the first verification template. [**]s the name implies, it is a sample made based on the appearance drawings and structure of the product before mass production. Generally, a small number of samples are made on the drawings first, which can be used to check the appearance or structural rationality of the product function template. So what industries are the precise users of the prototype factory and the prototype company?
Using the big data tools of the webmaster's home, we searched for these keywords and found that automobiles, home appliances, electrical appliances, toys, medical equipment, and industries with high demand for technology. For the production of prototypes and rapid molds in these industries, the commonly used methods in China are: CNC machining, SL[**], SLS, SLM, FDM, vacuum complex mold, low pressure perfusion, sheet metal production, we will define, use materials, software use, processable Compare these prototyping methods in terms of parts, advantages and disadvantages.
1. CNC machining
CNC machining is a computer numerical control machine tool, which is formed by cutting a whole plate by controlling the tool path according to the programmed program. It is currently the most widely used hand plate manufacturing method in China.
It is mainly used for the processing of plastic and metal sheets, and it can be cut on all sheets on the market. Cutting / sparking and other processes to achieve.
SL[**] is stereo light curing molding method, a kind of 3D printing technology, the materials used are mostly resin, and ultraviolet rays of specific wavelength and intensity are used
The laser is focused on the surface of the photosensitive resin to cure it layer by layer, and finally the layers are superimposed to form a three-dimensional entity.
[**]ll 3D printing is an additive technology, a process from 0 to 1. SL[**] is the earliest rapid prototyping manufacturing process with high maturity. Prototypes are directly made from C[**]D digital models. The processing speed is fast, the product production cycle is short, and cutting tools and molds are not required. Prototypes and molds.
SL[**] equipment is expensive and has high requirements for the factory environment. [**]fter the mold is formed, the strength, stiffness and heat resistance are limited, which is not conducive to long-term storage.
SLS is selective laser melting, a kind of 3D printing technology. [**]t present, the mature process materials are wax powder and plastic powder. When printing, the laser beam selectively sinters the flat powder, one layer completes the lowering of the powder box, and then lays a layer of powder for laser sintering, all sintered, take out the powder box and remove the excess powder, and a sintered part can be obtained. .
The prototype mold made by SLS has high strength and good toughness, and can be used to make bearings, gears, precision parts, and electronic parts.
The utilization rate of the material is high; but it is polluted in the process of prototype processing; the speed is relatively slow.
SLM is the selective laser melting molding technology, which is the most common technology in metal 3D printing. It uses a fine focused spot to quickly melt the preset metal powder, and directly obtains parts with any shape and complete metallurgical bonding, and the obtained production density can reach More than 99%.
In the process of SLM making prototype molds, since the parts are usually complicated, support materials need to be printed, and the support needs to be removed after the parts are completed, and the surface of the parts needs to be treated, so the production time will be longer and the cost will be higher.
FDM is the deposition molding method. The materials of FDM are generally thermoplastic materials, such as wax, [**]BS, nylon, etc., which are supplied in the form of filaments. The material is heated and melted in the nozzle. The nozzle moves along the section profile and filling trajectory of the part, while extruding the molten material, the material solidifies rapidly, and condenses with the surrounding material.
In the process of FDM making prototype molds, the price is relatively low, the materials are safe and harmless, there is no mold fee, and a variety of colors can be produced, but hollow products cannot be printed.
The prototype mold processed by FDM has obvious stripes, and the molding accuracy is relatively low. It needs to design and manufacture a support structure, and the molding time is long.
6. Vacuum complex mold
Vacuum complex molding is to use product prototypes (such as: SL[**] or hand plate processing) to make silicone molds in a vacuum state, and use PU materials for pouring in a vacuum state, so as to clone the same replica as the product prototype.
Vacuum lamination is the most commonly used prototype copying technology in the world; the technology can be used to change the material of product prototypes, assemble prototypes or carry out small batch production of products, etc., to meet the performance testing, marketing and delivery in the product development process. Inspection and approval requirements;
Different PU materials can be used to replicate rubber parts, transparent parts, high temperature resistant parts, etc. Ordinary PU materials are brittle and have poor toughness and high temperature resistance.
7. Low pressure perfusion
Low pressure injection molding, also known as low pressure reaction injection molding, is a new process used in the production of rapid molding products. [**]fter mixing two-component polyurethane materials, it is injected into the rapid mold under normal temperature and low pressure environment. bonding, curing and other chemical and physical processes
Process to form products.
Low-pressure perfusion generation prototype mold has the advantages of high efficiency, short production cycle, simple process and low cost. It is suitable for small batch trial production in the process of product development, as well as small batch production of relatively simple covering parts and large thick-walled and non-woven fabrics. Production of products with uniform wall thickness.
8. Sheet metal fabrication
Sheet metal production is the processing of metal plates such as steel plates, aluminum plates, copper plates, etc., including laser cutting, stamping, bending, etc. The remarkable characteristic of raw materials for sheet metal processing is that the thickness of the same part is the same.
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