Rapid prototyping and 3d printing

Rapid prototyping and 3d printing

Nov 25, 2023 | News Prosilas

The first physical output of a project

Rapid prototyping constitutes the initial phase of the physical production of a project, leveraging advanced technologies such as 3D printing.

Prosilas stands out as a leader in the field of rapid prototyping and additive manufacturing for over twenty years.

Prosilas stampe tridimensionali in carbonmide per prototipi rapidi

Photo courtesy : Bimota 

Photo courtesy : Armotia

Prototype: Definition and Utility

A prototype is the physical realization of an idea or project, an initial model created to evaluate both the aesthetic and functional aspects of an application.

What is Rapid Prototyping?

Rapid prototyping is the process of quickly creating a physical model of an idea or project.

This model, called a prototype, provides a tangible and visual representation of the application in the development phase. 3D printing has become a key technology for rapid prototyping due to its ability to rapidly translate digital designs into physical objects.

The primary purpose is to expedite the development process, enabling a comprehensive assessment of the performance and form of the product.

In Which Cases to Use Rapid Prototyping?

It is particularly useful in the early stages of designing and developing new products.

It is ideal when there is a need to quickly assess aesthetic aspects, optimize geometries, improve production cycles, and evaluate functional aspects.

Furthermore, it is valuable when exploring different iterations of a design without having to invest in expensive molds.

Un serbatoio funzionale realizzato con il materiale PA2200/poliammide, inizialmente progettato come prototipo per test di laboratorio e collaudi, è stato successivamente incorporato nel processo di produzione. La sua progettazione mirata lo rende adatto per il sicuro contenimento di liquidi corrosivi come benzina, gasolio, liquido glicole-etilenico, liquido freni e ATF.
Story of success of a 3D tank

Advantages

  • Reduction of Development and Production Times: 3D printing allows for the rapid translation of designs into physical prototypes, significantly reducing development times.
  • Cost Reduction: By eliminating the need for expensive molds, rapid prototyping with 3D printing helps contain costs in the design and development phase.
  • Improvement of Product Quality: The ability to assess aesthetic and functional aspects in an early phase enables continuous improvements to the final product’s quality.
  • Production Evaluation: With the initial step of prototyping, subsequent steps for mass production can be evaluated, allowing assessments of timelines and costs.

3D Printing Technologies for Rapid Prototyping:

There are various 3D printing technologies suitable for this service.

Among these, SLS (Selective Laser Sintering) and SLA (Stereolithography) are often used for creating prototypes with precise details.

Other approaches, such as using filaments or metal powders, offer different options based on the project’s requirements.

We provide our technological offerings based on project needs and assist the client in choosing the best solution.

Our capabilities

Photo courtesy : Bimota 

Case History Bimota

Bimota utilizes rapid prototyping in collaboration with Prosilas to expedite the development of its new motorcycle models.

Thanks to 3D printing, the design and testing process has become more efficient, reducing the time required to transition from the idea to the prototype from approximately 12 to 4 months.

Read the Case History
Dimensional Tolerances

Dimensional Tolerances

Nov 20, 2023 | News Prosilas

Tips & Tricks: What are Dimensional Tolerances?

Dimensional Tolerance in SLS 3D Printing: Management and Control by Prosilas

 

 

Dimensional Tolerances

3D printing has revolutionized the way products and components are manufactured, offering unprecedented flexibility and customization.

Even in this innovative technology, dimensional precision is a crucial aspect, and Selective Laser Sintering (SLS) stands out for its ability to produce parts with remarkable precision.

Dimensional tolerance refers to the possible deviation within which the printed part can vary from the original geometry.

Specifically, we are talking about +/- 0.3 millimeters for parts up to 100mm and +/- 0.3% for larger dimensions.

Watch the full video

Photo courtesy Protototal Industries

Thermal Expansion

This difference between the nominal dimensions in the 3D file and the printed part is due to thermal expansion, an intrinsic phenomenon in SLS technology.

This printing methodology involves heating the materials to their melting temperature, such as 170°C in the case of polyamide.

During the subsequent cooling process, the part transitions from the melting temperature to room temperature, contracting by approximately 3%.

Our Approach

The parts are initially processed with larger dimensions, using scaling factors specific to each machine and material.

The determination of these factors occurs through the periodic production of samples, a practice that allows monitoring and maintaining control over the dimensional tolerances declared to customers

L'approccio di Prosilas consiste nel produrre parti inizialmente con dimensioni maggiori, utilizzando fattori di scalatura specifici per ciascuna macchina e materiale.

To achieve the highest level of precision, we incorporate this element during the job preparation stage.

Quality Standards

Thermal shrinkage is not entirely constant; hence, an average of the results is calculated and applied.  This phenomenon can vary depending on various parameters, such as cooling times, part orientation, shape, and thickness.

To ensure maximum precision, we integrate this aspect during the job preparation phase. Geometries are carefully modified in the software, taking into account the inevitable dimensional variations that occur during material cooling.

This proactive practice demonstrates our commitment to providing 3D-printed components that strictly meet the quality standards required by our customers.

Per garantire il massimo della precisione, integriamo questo aspetto durante la fase di preparazione dei job.

The software undergoes meticulous modifications to the geometries, considering the inevitable dimensional variations occurring as the material cools.

What are the NDAs?

What are the NDAs?

Oct 18, 2023 | News Prosilas

NDA: The Value of Confidentiality Agreements at the Heart of a Trust Relationship Between Service Providers and Manufacturing Companies

Confidentiality Agreements, commonly known as NDAs (Non-Disclosure Agreements), are legally significant in the manufacturing industry as they are designed to protect confidential and sensitive information.

NDA contracts are widely used in both the industrial and technological sectors, as well as in research and development, with the explicit goal of preventing the disclosure of sensitive data to third parties without the explicit consent of the information owner.

Managing Industrial Secrets at Prosilas

Prosilas works closely with companies, contributing to the development of projects intended to launch in the market within the next three years. In this context, safeguarding information plays a critical role.

Therefore, we provide support for both prototype component production and mass production, utilizing a comprehensive range of technologies, ranging from complex additive manufacturing and 3D printing methodologies to more traditional injection molding techniques.

Watch the full video

Within the Prototal Industries group, we have privileged access to diverse technological resources, occasionally collaborating with external suppliers. This is precisely why it is crucial to extend confidentiality throughout the production chain when exchanging information with colleagues and partners.

 

Cybersecurity: Protecting Information Online

Information communication occurs through digital platforms or by transmitting files via email, emphasizing the relevance of cybersecurity issues.

In this regard, Prosilas consistently invests in enhancing its cybersecurity systems, ensuring adequate monitoring and protection of exchanged information.

Our staff also undergoes continuous specialized training to maintain high-level expertise in this field.

Dedicated Spaces: Protecting “Offline” Projects

Confidentiality is a fundamental pillar of our operations and is ensured through the use of NDAs. However, there are circumstances where a higher degree of secrecy is required. We have dedicated specific spaces within our laboratories, providing access exclusively to authorized personnel. Information security is an indisputable priority to preserve the trust and respect of our clients.

 

STL File : the most common errors

STL File : the most common errors

Sep 6, 2023 | News Prosilas

Normal lines inverted, holes and multiple shells

In this article, we will discuss the most common errors found in STL files, which usually involve inverted normals, presence of holes, and multiple shells.

These errors often result from mistakes during part modeling or during the export and conversion process to the STL file format using CAD software. These defects need to be corrected in order for the part to be suitable for printing.

As highlighted in the previous post, the STL file, necessary for 3D printing a part, represents a three-dimensional geometry composed of triangles oriented in space.

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Normal line inverted

Each triangle is described not only by the coordinates of its vertices, but also by the normal, which is a vector perpendicular to the plane on which the triangle is positioned, and its orientation defines the outer side. In some cases, the normal of these triangles can be inverted, mistakenly identifying an outer side as the inner side and vice versa. Such a situation can lead to errors during the printing process.

Example of a normal line inverted 

Example of a normal line corrected

Hole in the STL file

The second most common error encountered is the presence of holes, which can be caused by missing surfaces or misalignment between triangle vertices.

These holes need to be manually corrected if they are of considerable size, or automatically using specialized software if they are smaller. The presence of holes can compromise the quality and functionality of the printed part.

The presence of holes can compromise the quality and the realization of the part printing.

Holes in a STL file

STL file corrected

Shell Multiple

Lastly, we encounter the issue of multiple shells. A shell refers to a group of connected triangles. The presence of multiple shells in a part indicates the presence of separate groups of triangles. In this case, the inner shell overlaps with the outer shell.

Resolving this type of error is necessary to avoid anomalies during the slicing of the model into layers or incorrect surface generation, as well as to prevent printer jams. It is important that all shells are properly joined to achieve a coherent and functional printed part.

This situation can also occur when, in the design phase, the shapes that make up the CAD model are not properly integrated into the rest of the shell, but remain separate.

It is crucial to ensure that all components of the model are correctly integrated into the main shell to avoid printing issues and ensure the quality of the final product.

Example of Multiple shells

Example of Multiple shells

Multple shells fixed 

When we receive the files. stl from our customers, it frequently occurs the need to make changes and corrections before proceeding with the production.

STL correction requires specific skills and the use of dedicated software to repair imperfections and ensure that the part is ready for printing.

Our team is fully committed to making such corrections with the utmost precision and timeliness, in order to ensure that the printed parts reach high quality standards and fully meet customer expectations.

Additive manufacturing: from prototyping to 3D printing production

Additive manufacturing: from prototyping to 3D printing production

Aug 10, 2023 | News Prosilas

From Rapid Prototyping to Industrial Production: The Advantages of 3D Printing

3D printing, initially developed as a rapid prototyping technology, has now evolved into an established solution for serial production as well.

Thanks to its numerous benefits, industrial 3D printing can provide companies with a significant competitive advantage, allowing them to reduce development and production times, cut costs, and enhance product quality.

Prototyping

The term “production” is often not associated with 3D printing technologies, as the very nature of additive manufacturing systems, at least in their initial conception, was intended for the creation of individual pieces: models or prototypes.

In the early development phase, additive technologies facilitated the rapid creation of prototypes and aesthetic models, useful in expediting all testing phases, as well as research and development for new applications.

Production

Today, thanks to advanced additive manufacturing systems, it is possible to produce functional prototypes, small to medium batch productions, or even mass productions.

Advantages

Unlike the creation of individual parts or prototypes, additive manufacturing opens up highly advantageous scenarios that can improve and expedite aspects related to the development of new applications designed for mass production.

The main advantages of production with 3D printing can be summarized in five points:

1. Reduction of Development and Production Times:

3D printing allows for the rapid creation of functional prototypes, thereby accelerating the process of developing new products.

Moreover, even pre-series production with 3D printing can be carried out in much shorter times compared to traditional production technologies.

It is possible to introduce batches of components or objects into the market for collecting data from tests or feedback from end-users, facilitating the optimization of shapes or functions.

Prosilas si può stampare in 3d anche parti in metallo per la prototipazione rapida per il settore aerospace

For example, a company manufacturing components for the aerospace industry can use 3D printing to create functional prototypes within a few days, instead of the months or even years required by traditional prototyping technologies.

In this way, the company can expedite the development process of new aircraft and reduce development costs.

2.Cost Reduction:

3D printing can decrease production costs through the use of advanced materials and the reduction of material waste. Materials employed in 3D printing are often lighter and more durable than traditional materials, potentially reducing product weight and, consequently, transportation and energy consumption costs.

Additionally, 3D printing allows for minimizing material waste since the material is used only to create the necessary parts of the product.

Prosilas - Member of Prototal - PA 603 CF - nylon caricato carbonio - Racing - Motorsport - F1 - Moto GP

For instance, a company manufacturing components for the automotive industry can leverage 3D printing to produce lighter and more durable components.

This can contribute to enhancing vehicle efficiency, reducing fuel consumption, and promoting the metal-replacement process.

Our Materials

3. Quality Improvement:

3D printing can ensure greater precision and repeatability of products, enabling the creation of complex geometries and shapes impossible to achieve with traditional production technologies.

3D printing allows for the production of products with very tight tolerances, meeting the most stringent requirements.

Moreover, it can be used to manufacture products with intricate geometries that would be impossible to achieve with traditional production technologies.

Prosilas - Member of Prototal - PA 603 CF - nylon caricato carbonio - Racing - Motorsport - F1 - Moto GP

For example, a company specializing in medical prosthetics can utilize 3D printing to create customized prosthetics that perfectly fit the patient.

By employing 3D scanning technologies and reverse engineering, an exact model of the part can be created to tailor the prosthetic precisely to the individual’s needs.

More on toleraces

4. Product Customization:

3D printing enables the customization of products based on specific customer needs, creating unique and distinctive items.

With 3D printing, products can be crafted with personalized features such as dimensions, shape, color, or material. This can be a competitive advantage for companies aiming to provide their customers with unique and customized products.

For instance, a company manufacturing eyewear could use 3D printing to create personalized jewelry with unique shapes and colors.

Prosilas - Member of Prototal - PA 603 CF - nylon caricato carbonio - Racing - Motorsport - F1 - Moto GP

5. Production Flexibility:

3D printing is a flexible technology that can be adapted to various production needs, enabling the creation of products of any size and complexity.

3D printing can be employed to manufacture products of various sizes, ranging from small components to large objects.

With our industrial SLS printers, we can produce objects of considerable dimensions (680x370x540mm).

Furthermore, 3D printing can be used to create products of any complexity, including those with intricate geometries or shapes impossible to achieve with traditional production technologies.

Entrusting production to 3D printing offers significant advantages to companies in terms of reducing development times, controlling costs, improving quality, enabling customization, and providing production flexibility.

This technology is emerging as a versatile and innovative solution, allowing businesses to successfully tackle competitive challenges and respond effectively to market needs.

With proper workflow and optimized design, 3D printing continues to prove itself as a key catalyst for the evolution of the manufacturing industry.

More on Workflow
What is an STL file?

What is an STL file?

Jul 21, 2023 | News Prosilas

An Overview of the Three-Dimensional Representation for 3D Printing

Today, we delve into the analysis of the STL file extension and its crucial role in the realm of additive manufacturing. If you are interested in the world of 3D printing, you are likely already familiar with this extension and its unique characteristics.

 

Watch the full video

STL file

Essentially, the STL file represents a three-dimensional geometry through a combination of triangles arranged in three-dimensional space. This representation simplifies more or less complex surfaces, modeled using CAD software, into a series of planar triangles described by the Cartesian coordinates of their vertices.

 

The primary reason for the widespread use of the STL fileformat in the field of additive manufacturing lies in its ability to translate the language of CAD software, which is based on mathematical functions, into a format understandable by all 3D printing technologies on the market (SLS, SLA, FDM, etc.). This simplified format is based on a three-dimensional coordinate system, which represents a more accessible and immediate language for different printing technologies.

Export of  STL file

We often encounter the receipt of files with different extensions, such as .iges or .step, or even proprietary files from modeling software, each with specific characteristics. However, in order to materialize them through 3D printing, they need to be transformed into the STL file format. This conversion process simplifies the 3D models but may involve some modifications, such as approximating cylindrical or spherical parts and the presence of facets that do not accurately reflect the originally designed surfaces.

Example of 3D modelled file

Example of correctly exported file in STL with good resolution

Example of file exported in STL with incorrect resolution. Note the inside of the hole that has lost its initial sphericity.

STL file resolution

It is directly related to the number and size of the triangles that make up the model. A large number of triangles implies a higher resolution.

However, it is important to emphasise that a large file size does not necessarily mean significant advantages. Rather, it is preferable to adapt the size of the triangles to the printing resolution of the machine used. For example, our SLS machines operate with a resolution of about 5 hundredths of a millimetre. Therefore, it is vital to have a correctly adapted .STL file in order to guarantee optimum surface resolution.