How to Choose the Best CNC for Rapid Prototyping

GD-HUB contains other products and information you need, so please check it out.

Find the Best CNC for Rapid Prototyping

The road to insourcing your prototyping can be a long, yet knowledge-filled journey. Hopefully our previous discussions on rapid prototyping in-house have educated and inspired you to take the reins on manufacturing your own prototypes. Now it&#;s time to think about how to find the best CNC for rapid prototyping.

Once you&#;ve decided to take the plunge, where do you begin? After you&#;ve tackled the question of whether to use additive or subtractive methods, it&#;s time to start picking the machine that&#;s right for you. If you decided that a CNC machine is part of your solution, you&#;ve come to the right place! Let&#;s take a deep dive into the CNC universe and help make sense of it all.

How Do I Choose the Right CNC Machine?

Before looking outward for the right CNC machine, it&#;s best to look inward at your product line up. Understanding the requirements of your own products will help define what machine is the best fit for your prototype lab. Define what materials you&#;ll be working with, what dimensional tolerances you need to hold, and what sort of geometric features you need to create.

Besides the mere functionality of the machine, it&#;s also critically important to examine what it&#;s like with day-to-day use.

• Is the machine easy to use and maintain?
• Is programming the part inherently difficult?
• Will there be support available when you need it?
• What will it cost to power and tool up the machine?

What Are My CNC Options?

There is an extremely wide variety of CNC machines available for your consideration &#; it can be a daunting task when presented with all the options. Not to worry, though &#; this is where you fall back on the basic questions: tolerance, shapes, and materials. Keeping these in mind will help make choosing the right machine a lot easier.

Let&#;s break it down:

CNC Plasma Cutter

Commonly used for steel sheet metal, a CNC plasma cutter is an affordable, fast, and efficient way to burn through a variety of conductive materials. While there are some multi-axis plasma cutters on the market, they are commonly 2 axis machines. The drawbacks of CNC plasma cutters in rapid prototyping are its inherent limitations in 2 axis form, relatively poor cut quality, and hefty workplace safety requirements. Unless you&#;re enhancing a fabrication/welding process in your prototyping facility, a CNC plasma cutter is probably not your best bet.

CNC Laser Cutter

A step up from plasma, CNC laser cutters have grown in popularity in recent years and it&#;s easy to see why. Lasers can cut a wider variety of materials besides metal, including plastics, wood, and fabrics, all with relative ease.

As well, they can quickly create detailed (yet shallow) engravings. On top of that, they work very quickly and are typically cleaner, self-contained units.

However, there are some issues with using laser that need to be considered. Lasers use immense amounts of heat to break through the material, which can harden edges, making them more brittle. Also, despite being quite accurate, laser cuts will leave a slight taper on edges, which can hinder dimensional accuracy needs.

Since laser cutters are typically 2 axis machines, they are limited on what features they can create. While they can ablate away layers to create greater feature depth, they do so very inefficiently with regard to energy consumption and time, at the cost of potentially warping the part from excessive heat. This narrows the effective use of CNC laser cutters considerably, especially for rapid prototyping.

CNC Waterjet Cutter

Waterjet cutting is an effective way to cut thin or thick material of nearly any type. Using high pressure water along with an abrasive media, called garnet, water jet is a great substitute for laser or plasma cutting. It also creates less waste by using a closed-loop water circulation system. The downside to all of this comes with the cost of up-keep; maintaining filters, pumps, and nozzles can be a significant task. When comparing to CNC laser cutting, CNC waterjet is fairly inaccurate, typically only capable of holding a 0.005&#; tolerance, however, the cut quality may be nicer.

CNC Router

While routers are a type of CNC milling machine, they are usually categorized completely separately. This is primarily due to their design: CNC routers have a gantry frame construction, with a large bridge spanning over the machine table. This inherently allows for a large work envelope without sacrificing floor space. CNC routers are typically tasked with milling large panels of wood, plastic, or softer metals, like aluminum.

They also have the ability to mill with all 3 axis which allows for more complex features than the previous three machines, such as counterbores, chamfers, and pockets.

Keep in mind, if you&#;re new to the concept of machining, learning to use a CNC router will have a steeper learning curve than the other items mentioned. There&#;s a lot to learn about machine control, cutting strategies, milling tools, etc&#; Also, routers are typically disregarded by most machinists because of their lack of rigidity and accuracy, thus making them a distinct upgrade from CNC waterjet, but not quite as precise as a CNC mill.

CNC Lathe

Lathes are an essential part of the history of machining. Being called &#;mother of machine tools&#; dating back as far as the 13th century, lathes have since evolved to adopt CNC technology, and are still integral to manufacturing today.

Unlike the previous equipment, lathes are built to machine round parts exclusively. Where a CNC Router has stationary material and a spinning tool, lathes have spinning material and stationary tools.

This is highly ideal for cylindrical parts, like bolts, tubes, and washers, especially when very tight tolerances are necessary (less than 0.001&#;).

While a lathe is extremely capable and useful, it may not be your first choice when building your prototype lab. Unless your products are ideal lathe parts, like those mentioned above, a lathe is a bit too focused to be a well-rounded rapid prototyping machine.

CNC Milling

A CNC mill is one of the most common tools to see in a prototyping lab &#; and for good reason. Mills are robust, and flexible machines, that are suitable for a wider variety of parts and materials then the other machines mentioned. Allowing for complex features, like threaded holes, deep pockets, and 3D surfaces.

Typical CNC mills use a &#;C frame&#; design &#; a spindle that moves up and down, and a table that moves left/right and back/forth. With an extremely heavy build and large footprint, they are quite reputable for their precision, often holding tolerances of 0.001&#; or less &#; a quality that most of the aforementioned machines are not well known for.

Roadblocks to CNC Milling

The biggest hurdle to overcome with CNC mills isn&#;t &#;What can it make?&#;, but &#;Who can make it?&#;. There are layers of complexity to using a CNC milling machine &#; first, the operation of the control is an art unto itself. Typical CNC controls are extremely capable, but quite intimidating. With a vast array of buttons, switches and knobs, alongside a deep structure of software functions and menus, most controls will likely have you holding onto a user&#;s manual for dear life.

Then there&#;s the setup of the machine, which is a critical task for creating quality parts. This involves alignment of workholding to the machine&#;s axis, loading and measuring of tools, and setting correct program parameters. When done improperly, in the best case; you have successfully made scrap parts and need to start all over again. In the worst case; you have broken tools, workholding and machine &#; creating a serious dilemma and effectively making &#;rapid prototyping&#; an oxymoron.

Last, but not least, there&#;s programming. Aside from operating the machine, there&#;s a bit of skill required to programming a part in a CAD/CAM software. This, luckily, is getting easier all the time, with excellent options like Autodesk Fusion 360 which can simplify the process for new users. However, the hardest part is often not with applying toolpaths, but with setting the right parameters. Choosing the right cutting tool, feed rate, spindle speed, depth and width of cut, can be an uphill battle &#; and it changes by what material you use, and what features you make.

Striking the Right Balance

There are a lot of options, but the answer seems straight-forward; the most well-rounded rapid prototyping solution is CNC milling. However, the barrier to entry is real. Having an experienced CNC machinist on staff becomes a prerequisite, and as you may have heard, finding a qualified CNC operator is not getting any easier.

The issue is clear &#; there&#;s a skills gap in manufacturing that needs to be addressed, but even if drastic measures were introduced now, it will be many years before skilled labor starts in the workforce.

DATRON has been listening to this concern over the past decade, and they know just how to solve it.

While computer power and capability has made significant strides over the past decade, the typical CNC control has not. It&#;s still as cumbersome to use as ever, making alternative manufacturing technologies like 3D printing even more desirable. If convolution is the problem, then the solution is simple, or rather, the solution is to simplify.

CNC Milling for the Modern Era

Simplification is the goal with DATRON&#;s next control. Next is designed from the ground-up to focus on ease-of-use, without sacrificing industrial capability. With a familiar tile-based design, not unlike a smart , next is uncluttered and easy to understand immediately. Besides a pleasant visual design, next incorporates clever software engineering to make setup easy. The CAM Wizard walks you through loading the program, setting the tools, even probing the workpiece, as painlessly as possible.

Upgrading the control is just one way DATRON makes CNC milling more approachable. Setting up workholding has been optimized by utilizing a conical grid system, for quick and repeatable fixturing without any need to manually align. As well, accessories like vacuum tables make machining plate material quick and painless.

I know what you&#;re thinking. That&#;s all great, but what about the programming part? DATRON has that covered, too. To make every step of the journey easy, DATRON manufactures their own cutting tools, which are optimized for the machines they make. Likewise, they provide a full cutting parameter guide for their highly reputable line of single flute end mills.

I. Introduction

The automotive industry is among the greatest industries globally, and it consists of several competing companies. These companies have customers with different choices when buying a car. As the manufacturers, they have to meet the needs of the consumers by being innovative and coming up with appealing features. For that reason, prototyping is important since it gives the companies a chance to assess their various designs before producing them in large numbers.

In this guide, you will get to have in-depth knowledge about rapid prototyping and every aspect of automotive prototyping.

II. What Is Automotive Prototyping?

Automotive prototyping is the process that includes deciding on the material that best suits a certain product and evaluating the necessary items to be used in manufacturing the product. It also includes assessment and improvement to show that the final product is efficient enough for the consumer. This is done by producing an initial product sample that needs advancement and working to know the dos and don&#;ts.

For more information, please visit Rapid Tooling For Electronics Prototypes.

III. Why Prototyping in the Automotive Industry?

Prototyping is practiced in the automobile industry since it has many benefits that come with it. These benefits include;

• Prototyping makes it easier to find probable faults in a design early enough before mass production.
• It also makes it possible to evaluate if a company can implement the production of a certain product. This is by determining technical or any other limitations that may hinder the production process.
• It allows a company to get feedback from its customers. This is after presenting its customers with a prototype and getting their view on what to improve or change hence better customer satisfaction.
• It saves on the costs to be used in case of any required changes since customer feedback helps the company make changes early before mass production, which would otherwise be costly.
• The period a product is expected to last is determined through the assessment of the prototype.

IV. Functions of Automotive Prototyping

The functions of automotive prototyping include;

A. Design validation

In this phase, the manufacturers present roughly done prototypes to stakeholders for them to have an idea of the concept of the product to be manufactured. Cost-efficient and simple manufacturing processes such as mold design and mold manufacturing are used in this phase to create the draft prototype.

B. Pre-manufacturing

This takes place after the draft presented in the first phase is verified. It is also referred to as the mule phase and it is in this phase, a better prototype is manufactured using the CNC machining method, which is commonly used. This phase helps the engineers to have a picture of how the prototype will connect with other parts in a former vehicle. Other design options are considered to see which one suits better.

C. Production or manufacturing

As the name suggests, in this phase the engineer goes ahead to choose the perfect procedure to use in the production of the end product. Once the most favorable method is chosen, the production process of the prototype begins.

D. Customer feedback

When the prototype is manufactured, the manufacturers provide the product to their customers for testing and later give their feedback. Customer feedback helps the engineers know what to change and improve according to the customer&#;s preferences. This also helps stakeholders get the idea the engineers had in mind.

E. Safety testing

In this phase, the automotive prototype is tested to assess its durability, how safe the user is when using it, and also the likelihood of failure. To ensure reliable results, the prototypes are exposed to different serious conditions to recognize any complications that may hinder the efficiency of the product or be unsafe to the customers. The testing process can be referred to as Failure Mode Effect Analysis.

F. Manufacturing validation

A prototype has to be developed in this phase for manufacturing validation. This is whereby the engineers use the equipment that was initially suggested to be suitable for the production process. Some adjustments are made in this phase to complete the automotive product. Eventually, when the final prototype is considered to be secure for the customers and working well as expected, production can start and products be sold to the public.

V. Methods of Creating Automotive Prototypes

A. CNC Machining

This process is used in manufacturing the first piece of a product that is yet to be manufactured in large numbers. This process helps ensure that problems and flaws are easily recognized to ensure no further problems during the manufacturing process. It helps visualize how the end product is expected to look and its qualities. It involves a computer spontaneously directing a machine tool instead of being manipulated directly by an operator.

B. 3D Printing

This is whereby a three-dimensional object is built out of a CAD model. Several procedures can be used whereby the material is placed, attached, or hardened under computer control while materials such as plastic, and metal are put together layer after layer. 3D printing is normally used for rapid prototyping.

C. Vacuum Casting

It makes use of silicone molds to produce elements of rubber and plastic under vacuum which makes it manufacture products with smooth surfaces and of high quality. Vacuum casting can also be used in rapid prototyping only CNC machining and 3D printing give prototypes of better quality than vacuum casting.

There is also mold manufacturing which involves melted plastic being put into a mold and unlike vacuum casting, the mold is usually under high pressure.

VI. Roles of Prototyping in Automotive Design

Automotive prototyping is used to come up with a simple prototype to show how the end product is expected to look and work. A prototype is considered the initial step in helping to confirm the viability of a product. The roles of prototyping are divided into three types as discussed below.

A. Manufacturing an appearance prototype.

An appearance prototype refers to a prototype being assembled to resemble the end product in terms of the desired shape, size, color, and image. It is usually made almost at the end of the cycle following revisions of the presented designs. Appearance prototype is often used to come up with marketing materials during the production process.

B. Manufacturing a structural prototype.

This type of prototype is produced through the CNC machining or 3D printing method. It is normally used to test and see if the product can function as required. This is done by the prototype having the suggested size and using the method of installation suggested to identify any problems and work towards solving them. It helps the engineer to see if the structure is rational or not.

C. Manufacturing a functional prototype.

This type of prototype is produced right before the actual production process to prove that the design used is the right one for the product. They are made as a complete replica of the end product to be produced for the public with the right materials used, in terms of quality and durability. The engineer can test the expected product&#;s efficiency and ability to perform well under the utmost working conditions.

VII. Materials Used in Automotive Prototyping

The various materials to be used are decided upon depending on the different parts to be made and the different design stages. These materials include plastic, metal, and silicone.

A. Metals in Automotive Prototyping.

The most often used metals are aluminum and steel in prototyping, although titanium, magnesium, chrome-based alloys, and other kinds of metals can be used when needed for specified applications. Metals are preferred due to several advantages which include them being versatile, cost-effective, great strength, and high heat resistance.

B. Plastic in Automotive Prototyping.

Automotive plastics are acknowledged because of their versatility and high performance. Also, their light nature makes them consume less fuel. The commonly used plastics include;

-polypropylene which does not easily react to chemicals or heat, making it convenient for its tasks in an automotive.

-polyurethane is also versatile and is very suitable for insulating and can easily be molded.

-polyvinyl chloride which does not easily react with water or chemicals, is durable and cost-effective and can highly resist impact.

-Acrylonitrile butadiene styrene. It consists of acrylonitrile, butadiene, and styrene put together through ABS injection molding. It has properties that make it long-lasting, strong, and suitable for electric insulation.

Other plastics include; polyamide, polystyrene, polyethylene, polyoxymethylene, polycarbonate, acrylic, polybutylene terephthalate, polyethylene terephthalate, and acrylonitrile styrene acrylate.

C. Silicone in Automotive Prototyping.

This is whereby rapid prototyping makes use of silicone molds to create some prototype parts. Sometimes the procedure might require putting polymer inside a silicone mold which is semi transparent. Transparency is important since it makes it possible for the producer to see and make sure that the polymer has reached all the desired areas in the other components. Silicones are preferred due to their ability to not tear easily, transparency, and high resistance when they come in contact with chemicals.

VIII. Application of Prototyping in the Automotive Industry

The automotive industry has been using prototyping in the production process for years and it still helps manufacturers of cars to come up with new designs and understand the consumers. The first car to be made using a prototype was called Model T. The Ford Motor Company first used a prototype of the desired car to examine the different features of the designs presented before producing for the public. Today, car manufacturing companies have fully embraced the idea of prototyping before mass production when trying out new designs and innovations.

IX. Future Trends in Automotive Prototyping

We&#;re in the 21st century and different technologies keep being invented therefore automotive companies too have to embrace technology and new designs.

A. Advanced manufacturing technologies

Business rule 101 is that for a product to be a success once released to the market, the manufacturer has to be able to deal with competition from other companies. To come up with a high-quality product, the determining factor is usually the time taken to manufacture it and the amount of money used on it. There are methods of production that favor both time and the money allocated for the production such as rapid automotive prototyping. There is a new technology used in the manufacturing of automobiles which is known as Massivit Pro 3D. This has made it possible to make bigger products and more outright ones than before and takes a very short amount of time.

B. Integration of AI and machine learning

The automotive industry is getting some positive changes from Artificial Intelligence and Machine Learning. AI is focused on carrying out duties that need the intelligence of a human being while Machine learning can be defined as a tool that enables a machine to decide on its own based on its previous occurrences of similar events. These two are being implemented in the production process of automotive, design, supply network, and other activities that arise after the production process. Also, they are being applied in the systems created to assist drivers and deal with risks. AI also is being put to use in the insurance sector and maintenance of automobiles.

C. Sustainable and eco-friendly materials

The automotive industry is advancing from using some materials used in the past which are hard to reuse. Electrifying automobiles is a means to help reduce the amount of carbon emitted by vehicles. Car manufacturers have for some years now been using synthetic leather instead of just normal leather. Lately, they are considering the use of vegan leather which is more environmentally friendly. The companies are also considering recycling plastics due to their harsh effects on the environment and using them to manufacture various parts of a car such as airbags. Also, using bio-based materials will help reduce the weight of a car, making its performance more efficient.

X. Conclusion

Over the years, automotive prototyping has proven to be very resourceful, and interaction with customers through the production of prototypes has made it possible for manufacturers to understand where to change and improve. Accepting and practicing automotive prototyping is advisable for better products and responses from the market. Prototyping ensures that the customers get quality end products and that the products are safe for use.

For more low pressure injection overmoldinginformation, please contact us. We will provide professional answers.