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Physical Prototypes
While computer simulation is a valuable tool in our arsenal, we strongly recommend the creation of prototypes. There is no substitute for holding the actual product in your hands and being able to play with it. This is another important step in eliminating iteration - changing the parts after tooling is completed is both time consuming and expensive, and can limit the options available to fine-tune the design.
Depending on the type of product and desired purpose of the prototype, there are several techniques that can be used:
Fabrication
The ‘traditional’ method of model-building is still frequently used. Stock sheets and blocks of material is machined into the desired shape. This can be an excellent method for creating one or two prototypes quickly, in the correct material.
Rapid Prototype
Rapid prototyping machines automatically create models from 3D CAD data. There are a variety of techniques, including SLA, SLS, and FDM, but they all operate on the same principle of building up a part layer by layer. Each of these systems has different strengths and weaknesses depending on the size and physical properties required of the prototype.
Casting
When many prototypes (5-50) are required, GRT-Mars uses urethane casting techniques. A master pattern part is created using rapid prototyping or fabrication, with appropriate shrinkage factors built in, and then a rubber mold is cast around the pattern. Urethane is then cast in the rubber mold to create the finished prototype parts. Urethanes are now available with a wide variety of material properties that give a good approximation to the finished part under many circumstances.
Sheet Metal
GRT-Mars works with several specialists in creating short-run stamping prototypes, ranging in size from battery contacts to large panels.
Electronic Prototypes
Electronic prototypes are much simpler and less expensive to create than their mechanical counterparts. Bare prototype printed circuit boards can be created in a day or two, and then assembled with the actual components.
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