Advancing rapid prototyping technology
Rapid prototyping (RP) refers to the group of techniques that facilitate the development of a product using computer-aided design (CAD) and 3D technology. Various prototyping machines exist that allow construction of parts and prototypes allowing rapid product dissemination to the market. However, special skills are needed for the high end RP techniques, and the machines are expensive and not easily adjustable to an office environment. To address these issues, the EU-funded ‘Development of an innovative, modular rapid prototyping system for rigid and flexible models’ (Flexrap) project aimed to develop a high quality rapid prototyping system with more flexibility and functionality than the stereolithography (SLA) type of systems. Project partners worked on various parameters of prototyping machines including the support material that could be easily removed in an office environment while giving sufficient strength. The type of model material used (hard or soft) was also investigated, giving special emphasis to resin formulations which had to comply with the proprietary ink-jet technology. A major breakthrough was the development of a flexible formulation with a high elongation at break and good elasticity that was successfully introduced on the market by project partners. Additionally, an experimental printer was built that could print two model materials and one support material and the applicability of the new prototype machine was investigated. Successful applications of the Flexrap technology were found in the foundry, toy and footwear industries.
