Coming to market first in any industry is imperative to the initial success of a product line.
Whether the industry includes the newest, tech-savvy gadget or old technology reimagined, 3D scanning for rapid prototyping is one of the fastest routes to test a design.
Rapid prototyping allows for a company or inventor to validate fitment, design, and processes before the innovation is manufactured. Depending upon the process chosen, prototypes can be made just hours after a CAD file is produced.
Designers can find problems instantly. This lowers the risk wasting thousands of dollars in machining, mold making, or marketing.
3D scanning for rapid prototyping applications is changing the way prototypes are created and tested, allowing for faster, more efficient product development cycles.
Here’s how 3D scanning for rapid prototyping can help you come to market first.
What is 3D Scanning for Rapid Prototyping?
3D scanning for rapid prototyping involves using advanced scanning technology to create precise digital models of physical objects.
A 3D scanner can record data on any physical object with even the most complex geometries. This data is then used for conceptual purposes in mesh format or reverse engineered to create manufacturable CAD files.
Although most are familiar with CAD models being specifically for processes like laser cutting or machining, these models can then be used to produce prototypes through additive manufacturing, commonly known as 3D printing.
This process, also referred to as rapid prototyping, involves building objects layer by layer based on the digital design, whic
h is the opposite of traditional subtractive manufacturing that cuts material away.
How Does 3D Scanning for Rapid Prototyping Lower Time to Market?
3D laser scanning accelerates the creation, testing, and refinement of prototypes, enabling companies to launch their products more swiftly.
3D scanning provides rapid and precise digitization of physical objects. Traditional measurement and modeling methods are time-consuming and prone to errors, whereas 3D scanners can capture detailed geometries quickly and accurately.
This precise data capture reduces the need for extensive manual measurements and revisions, speeding up the initial design phase.
Additionally, the detailed digital models generated by 3D scanners can be directly used for additive manufacturing, streamlining the transition from design to prototype.
This seamless integration minimizes delays, allowing for quicker iterations and faster identification of design flaws, ultimately leading to a shorter overall development cycle.
Types of Rapid Prototyping Processes
There are several types of rapid prototyping processes, each suited for different applications:
Binder Jetting
Digital Light Processing (DLP)
Fused Deposition Modeling (FDM) or Material Jetting
Laminated Object Manufacturing (LOM) or Sheet Lamination
Selective Laser Melting (SLM) or Powder Bed Fusion
Selective Laser Sintering (SLS)
Stereolithography (SLA) or Vat Photopolymerization
Advantages of 3D Scanning for Rapid Prototyping
Why can’t a CAD engineer just create files in a computer and hit print?
Most products are multifaceted and include complex geometries that are hard to draw in a CAD software. A 3D laser scanner can instantly create a mesh highlighting any detail in a physical design, allowing a CAD engineer to have it on-screen in seconds.
Read an article here about 3D Scanning: From Mesh to CAD Conversion
This is especially helpful if a design is building off of an existing component. For example vehicle body aesthetics off existing bumpers or hoods.
To list, here are some of the major advantages of using 3D scanning for rapid prototyping.
1. Faster Production
3D scanning for rapid prototyping significantly speeds up the production process compared to conventional methods like injection molding and subtractive manufacturing.
From initial design to final product, this technology allows for quick testing and refinement of ideas. Rapid prototyping means you can iterate faster, ensuring your product reaches the market ahead of competitors.
2. Enhanced Accessibility
With the growing popularity of 3D scanning and printing, software and hardware have become more user-friendly and accessible. This democratization of technology means that businesses of all sizes can integrate 3D scanning for rapid prototyping into their production cycles, often within just a few days.
3. High-Quality Prototypes
Traditional manufacturing methods can sometimes lead to poor-quality prototypes. In contrast, 3D scanning for rapid prototyping ensures high precision and better design fidelity.
By building objects layer by layer, this method enhances the quality of prototypes, resulting in more accurate and reliable
products.
4. Tangible Design and Effective Testing
3D scanning for rapid prototyping provides both a virtual model and a physical prototype, allowing for thorough testing and evaluation. This dual capability helps identify and rectify design flaws early in the development process, leading to a more refined final product.
5. Cost-Effective Production
Reducing labor costs is a significant advantage of 3D scanning for rapid prototyping. Traditional prototyping methods often require extensive manual labor and high costs, especially with production runs and injection molds.
3D scanning simplifies the process, requiring only a few operators to manage the printing, thus lowering overall expenses.
Applications of 3D Scanning for Rapid Prototyping
Initially, rapid prototyping was thought of only being used in the automotive industry for building parts and scale models. However, its application has expanded to various fields, including medical, aerospace, and product design industries.
Product designers, in particular, benefit from this technology as it aids in the design, development, and visualization of products before mass production.
How 3D Scanning Accelerated Rapid Prototyping for An Industrial Combustion Company
Industrial combustion is not a new technology. However because of this legacy technology, many designs and patents have never been updated or cataloged
Our client recently faced a challenge in developing a new gas burner that would be used in commercial food production. Their last product had not been produced in a decade and would require major retrofitting.
The Challenge
The new gas burner needed to be distributed within six months, a timeframe that demanded rapid prototyping and quick iterations. Design changes would include fitting up old parts to new.
Traditionally, prototyping methods proved too slow and error-prone, making it difficult to keep up with the aggressive schedule.
The company needed a solution that could provide accurate prototypes quickly. This allows for seamless modifications based on testing and feedback.
Implementation of 3D Scanning
As a new client, our company quickly recommended and integrated 3D scanning into its rapid prototyping process.
By scanning an existing design, we were able to visualize the main functionality of the gas mixer and start analyzing where design could be improved. Here are the ways 3D scanning was used specifically for this project:
1. Rapid Data Capture
Using a blue-light laser scanner, our engineering team could quickly capture detailed geometries of initial mock-ups and components. This step drastically reduced the time spent on manual measurements and data entry, providing precise digital models in a fraction of the time.
2. Enhanced Design Accuracy
The detailed digital models generated by the 3D scanners allowed for precise modifications and enhancements. Engineering could easily identify and correct flaws in the early stages, ensuring that each prototype iteration was more refined and closer to the final product.
3. Seamless Integration with CAD Software
The 3D scanned models are post processed, reverse engineered, and were directly imported into CAD software, facilitating smooth transitions between design and prototyping phases.
This integration enabled quick adjustments and immediate re-scanning of modified parts, keeping the development process fluid and dynamic.
These CAD files were now in universal formats, saved for future projects, and also used for quoting purposes.
4. Rapid Prototype Creation
The new designs that were created using legacy parts and 3D scanning were now able to be 3D printed. Using the SLS layering method, the 3D prints were successful and correct in measurement. From here our design engineer team was able to test fit off-the-shelf hardware and retrofit to existing application points.
With the complexity of the gas mixers, rapid prototyping by 3D printing offers a cost effective way to see the new product in reality before ever having it quoted by machining.
The price difference between a 3D printed prototype versus machined part was over $1000!
Results of 3D Scanning for Rapid Prototyping
The implementation of 3D scanning yielded impressive results for the gas mixer project by the following:
Reduced Development Time:
The time to create and refine prototypes was cut by 50%, allowing the team to conduct more iterations and improve the design within the six-month window.
Cost Savings
By minimizing manual labor and reducing the need for multiple physical prototypes, the company saved significantly on production costs.
Improved Product Quality
The ability to rapidly test and refine prototypes led to a higher-quality final product, with fewer defects and better performance.
Faster Time to Market
Our industrial combustion client successfully launched the new gas mixer ahead of schedule, gaining a competitive advantage and capturing early market share.
This pace allowed them to pre-sell units before completion and forecast out how many to order in the future.
Conclusion
This case study highlights the transformative potential of 3D scanning technology in bringing high-quality products to market faster, demonstrating its value as an essential tool in modern manufacturing.
3D scanning for rapid prototyping is revolutionizing product development by enabling faster, more accurate, and cost-effective production of high-quality prototypes.
Conclusively, by adopting this technology businesses can stay ahead of the competition and bring their products to market more swiftly than ever before.
