Imagine creating a part inside of a computer and then being able to hold and evaluate that part 45 minutes later. What would have been inconceivable 20 years ago is now well established technology. Three-dimensional printers make it possible.
The old school method of creating prototypes involved first creating two-dimensional drawings of a part and then taking those drawings to a model maker to create the prototype. The model maker would first have to correctly interpret the drawings (assuming that all of the necessary information was shown), and then a process for creating the prototype was identified. This process could be as simple as cutting metal with a band saw to as complicated as creating an injection mold. After the part was created, the smart engineer would have the part carefully inspected and measured to make sure that it fell within the specifications on the drawings. If it didn't pass inspection, the part would need to be modified or, worse yet, scrapped and the entire process would start all over again.
Whew! The memory of it all is enough to give me nightmares, but thankfully, technology has provided an alternative... and what a spectacular alternative it is. Imagine taking the same part that took days or weeks to create and having it in your hand in 45 minutes. Consider the following process using the "new school" method.
A part is created digitally inside of a computer using 3D modeling software. The file is then saved in a common format and sent to a 3D printer. The printer builds the part one thin section at a time from the bottom up putting water soluble supports in where necessary. It takes from 20 minutes to several hours to complete depending on the size and complexity of the part. The part is removed from the printer, placed in a detergent solution to dissolve the supports, rinsed, dried, and is back in the engineer's hands the same day. The dimensional accuracy of the part is in fractions of a millimeter, so most parts do not require additional measurement and verification. Bing... bang... done!
It almost sounds too good to be true. The printers must be RIDICULOUSLY expensive, right? Wrong. These printers have become relatively affordable in recent years, and while there are still models costing upwards of $250,000, there are very functional 3D printers between $20,000 and $40,000. Weigh that against the old school method of creating prototypes, and it doesn't take long for the material, time, and labor savings to make a 3D printer a money making move for many businesses.
3D printers are by far one of the most intriguing components of Digital Prototyping, and I love watching people stand transfixed as they watch the printer quietly build the part one layer at a time. The parts don't exactly materialize before your eyes, but when the printer door opens, and a functional part comes out, the reactions of the spectators would make you think it had just come out of a Star Trek replicator. The technology is not quite that advanced, but it is definitely very, very cool.
Tek Lentine is an expert in the field of Digital Prototyping and other hi-tech business solutions. Tek currently works as an account manager for Hagerman & Co offering not only Digital Prototyping software and hardware but also training and consulting expertise in the areas that he writes about. You can contact Tek with questions or comments by email at TekLentine@Hagerman.com or on his cell phone at (574) 386-7279. Be sure to check out Hagerman & Co's web site at http://www.hagerman.com/
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