ProtoCAM Rapid Prototyping Blog

ProtoCAM Customers Win Using Rapid Prototyping!

2012-12-11T15:15:00.000-05:00

Congratulations to the winners of the Lehigh Valley Business of the Year awards. Many of our valued local customers were nominated, and two of them won!

EcoTech Marine took top honors for businesses of 26-100 employees, and XiGo Nanotools captured Emerging Business of the Year.

ProtoCAM is honored to have been chosen as prototyping partner for each of these companies. Using our rapid manufacturing processes enabled them to quickly take their innovative designs from concept to award-winning production.

Their successes demonstrate effective use of the rapid prototyping process. In short:

* have a great idea
* engineer your concept well
* rapid prototype your parts to validate design
* adjust design elements as needed
* produce a fantastic product

As shown by EcoTech Marine and XiGo Nanotools, combining the process above with a great management team and a reliable rapid manufacturer like ProtoCAM, positions companies for recognition and success.

Contact us today and let us help you earn the recognition you deserve!

Dimensional Tolerances for Rapid Prototypes / Parts | #6 in FAQs Series

2012-10-03T13:11:00.001-04:00

This is the 6th in a series of FAQs

Topic #6 – What level of dimensional tolerance accuracy can rapid prototyping produce?

Attainable dimensional tolerances depend on the choice of technology used to make the prototype or part. The most requested rapid prototyping processes by ProtoCAM’s customers include: stereolithography, laser sintering, urethane casting, RTV molding, and Polyjet 3D printing.

As with other factors in selecting an additive manufacturing method, the process choice depends mainly on the intended application or use for the prototype. Our engineers can help determine the most appropriate choice based on project requirements such as mechanical stresses to which the part will be subjected, fit accuracy requirements, and aesthetic needs.

Typically, dimensional tolerance is an important consideration if the part is going to be used in production, or it has to fit exactly with other parts.

Stereolithography provides the tightest dimensional tolerances of any rapid prototyping/additive manufacturing technology. Published tolerance s for stereolithography (SLA) are +/- 0.005” (0.127mm) for the first inch, and an additional 0.002" for each additional inch. Part geometry and build orientation can also have an effect on tolerances. If dimensional tolerance is a critical factor, SLA is typically the best choice.

Laser sintering provides good dimensional tolerances as well. The typical published tolerances for non-metalic laser sintered part are +/- 0.007” (0.1778mm) for the initial inch, and 0.003” (0. 0.0762mm) for each additional inch.

Polyjet 3D printing is typically not a good choice where dimensional tolerance is an important consideration, nor is any casting or molding technique.

ProtoCAM excels at helping customers with tough engineering/design questions like this. As always, to find out the specific answer to your question about dimensional tolerances for your project, just contact us!

ProtoCAM in LVB Article on 3D Printing/Additive Manufacturing

2012-08-20T07:39:00.000-04:00

The Lehigh Valley Business (LVB.com) article on August 17, 2012 - Manufacturing firms find cost-effective way to create new products - features quotes from Ray Biery and Ron Belknap, ProtoCAM's Managing Partners. The article describes how some companies are embracing 3D Printing / Additive Manufacturing for innovation, versatility, efficiency and speed in product development. From the article:

Northampton-based ProtoCAM is a rapid prototyping service bureau that has helped many clients benefit from 3-D printing. Company officials said more companies are demanding the service. "It’s already saved companies thousands of dollars per project," said Ray Biery, managing partner for ProtoCAM. "These companies have a need to see their product in a relatively short period of time."

All of ProtoCAM’s marketing is done via the Internet. The company is capable of shipping several hundred parts a day from its Northampton site. Every object that the company produces started as a 3-D computer-aided design (CAD) model. Additive manufacturing comes into play when the elements are added layer by layer, said Biery. "A lot of the things we make are used for finished products," said Biery. The company has a two-day lead time and can ship an order within two days or provide same day delivery, said Biery. Each of its six 3-D printers cost about $500,000, making for a $3.5 million total investment in 3-D printers, said Ronald Belknap, managing partner.

With its vast experience as a rapid prototyping services provider, ProtoCAM continues to take a leading role in using 3D printing and advanced additive manufacturing technologies to benefit customers. Contact ProtoCAM to find out how ProtoCAM can assist with product development that is fast, innovative and effective.

Small Metal Prototypes Press Release

2012-06-29T12:27:00.002-04:00

ProtoCAM's press release today announces:
ProtoCAM Expands Small Metal Prototypes Rapid Prototyping Services

Visit ProtoCAM's Metal Rapid Prototyping page for more information on small metal prototypes.

Or contact ProtoCAM for a quote for metal prototypes.

Selecting the Best Rapid Prototyping Technology for Your Project | #5 in FAQs Series

2012-04-27T10:33:00.001-04:00

This is the 5th in a series of FAQs - Frequently Asked Questions - that ProtoCAM hears from customers who call or email. Topic #5 - What technology should I use to create my part or prototype?
There are many choices, including stereolithography, laser sintering, urethane casting, RTV molding, Polyjet 3D printing, and more.

Some customers already know exactly what they want when they request a quote; typically these are experienced product designers and engineers. ProtoCAM is always ready to reply with a fast quote in these cases.

Many other customers contact ProtoCAM and ask for our advice on choosing the best way to make their part or prototype. In these cases, ProtoCAM excels at providing recommendations that best satisfy the requirements and specifications, while keeping the project cost-competitive.

The most important factor in selecting appropriate technology is the intended use of the part(s). ProtoCAM offers a wide variety of technologies to meet almost all rapid prototyping and additive manufacturing applications. The primary attribute requirements to consider include: dimensional precision, surface finish, durability, flexibility, opacity, coloring, etc. Some customers are driven more by speed or cost. ProtoCAM's breadth of production offerings, and depth of engineering expertise, can help customers define and accommodate nearly any combination of the above project requirements.

While each project and part must be evaluated individually, below are some general guidelines on selecting the best technology for a prototype or part:

Stereolithography is typically the best choice when aesthetics, small details and dimensional tolerance are critical.
Laser sintering (plastic, not metal) is typically the best choice when mechanical strength is important but aesthetics are not as important.
3D printing with Polyjet provides a good blend of small detail, mechanical strength, and aesthetics.
Urethane casting / RTV molding are often selected for short run production when the production material is going to be a plastic injection molded resin. Clear parts/prototypes are possible with urethane casting and RTV molding.

(Note: dimensional tolerance will be the next topic in this FAQ series, so check back for more info on that.)

In all cases, ProtoCAM brings vast engineering expertise, years of experience and familiarity with many different industries and applications to every recommendation on the choice of technology.

As always, to find out the specific answer to your question about selecting the best rapid prototyping or additive manufacturing technology for your project, just contact us!
++++++++++++++

Speeding Product Development - Rapid Prototyping with ProtoCAM

2012-04-16T16:50:00.000-04:00

Charles Waugh of WOXOM approached ProtoCAM to help prototype his new innovation - the SlingShot - a smartphone accessory to improve video quality by making it easier to keep the camera steady. It uses a flexible cradle (video below), designed to fit almost any smartphone, which attaches to a handle (video below) with built-in ball swivel and super slick pop-out feet. The cradle attaches via a 1/4-20 threaded insert, allowing the cradle to mount not only to it's own handle, but any standard tripod.

Charles had already tried other rapid prototyping technologies but didn't get quite what he needed in terms of quality. ProtoCAM discussed his needs and determined that Accura 25 would be the most appropriate rapid prototyping material for this project. It provided tight tolerances, a high quality finish, and the ability to ship only a couple days after ordered. Now, after only a few days on Kickstart, the project is fully funded and heading to commercial production!

As with many of our customers, Charles was excited to see his creation come to life. He even made a video which shows not only the parts for his project, but also the care with which ProtoCAM packages parts for delivery.

3D Printed Parts Arrive from ProtoCAM from XOMOM / Charles Waugh.

We see many innovative designs, but this one in particular caught our eye for the elegance of feature implementation. Check the WOXOM website and Kickstarter project page for more details. We were so impressed, we ordered a few SlingShots to test and use in the office.

Congratulations to WOXOM for meeting their KickStarter funding goal, and to Charles for his great design work! ProtoCAM was happy to play a part in the rapid product development for the Slingshot.

If you have a great project to build, or success story you'd like to share, drop us a line. We love to hear about and share the amazing things our customers are doing.

The SlingShot by WOXOM from WOXOM / Charles Waugh.

SlingShot Cradle from XOMOM / Charles Waugh.

SlingShot Handle from XOMOM / Charles Waugh.

Largest Prototype, Smallest Part That Can Be Produced via RP | #4 in FAQs Series

2012-03-22T16:23:00.000-04:00

This is the 4th in a series of FAQs - Frequently Asked Questions - that ProtoCAM hears from customers who call or email. Topic #4 - Size of Part / Prototype. The first three in the FAQs series were focused on process-type questions: 3D CAD files, quoting and pricing. The next few FAQs will address technology questions.

Customers often ask about what part/prototype SIZE is possible. Size constraints vary among different additive manufacturing techniques. Since stereolithography (SLA) is the most popular among our customers, we’ll answer in terms of what can be done with SLA technology.

The largest stereolithography (SLA) part that ProtoCAM can produce in ONE piece must fit within a 25.6" x 29.5" x 21.65" envelope, but we can, and have, built much larger parts. For these larger parts, we divide the CAD file into sections that can be made as individual pieces, then produce the part in sections. When all sections are completed, we assemble it using a variety of techniques.

The assembly choice is typically driven by how the part or prototype is going to be used. If it’s simply a display model, we may use an adhesive to combine the parts. If more strength or durability is required, parts can be pinned, braced, or joined with threaded brass inserts - view this previous blog for more details on this topic.

Some of our molding projects, such as the one pictured above, are big enough to require chain hoists and forklifts to maneuver! The art piece to the right measured about 6 feet across (shown here packed for safe transport to gallery.)

The smallest part ProtoCAM can build is constrained only by the limits of our Viper si2 stereolithography machine’s high resolution mode. For example, we built the following part a few days ago measuring only .075” x .075” x .035”.

As always, to find out the specific answer to your question about your part, just contact us!

Rapid Prototyping Price / Rapid Prototype Cost | Part #3 in FAQs Series

2012-02-06T13:15:00.002-05:00

“What does rapid prototyping cost?” is the third in a series of FAQs - Frequently Asked Questions. ProtoCAM frequently hears this question about pricing for prototypes / parts from customers. As in many cases, the answer is - “It depends”. What does it depend on?

The price that ProtoCAM quotes for a prototype mainly depends on:

Physical size of the part, particularly the height of the part
(shorter parts cost less)
Volume - how much material is in the part
(costs increases with volume)
How many parts are being ordered
(unit cost typically lower for batches)
Special finishing, coloring, handling or post-production processing required
(premium finishing services available)
How fast the part is needed
(expedited services available)

In the previous FAQ #2 blog post on rapid prototype quotes, we talked about what we do to process your request. Of course, the price is a big part of the rapid prototyping quotes we provide. All of the above factors are considered in providing a competitive quote, which is another reason why we don’t do instant online quoting; they mainly rely almost entirely on size and volume to create a quote.

By contrast, ProtoCAM adds a level of expertise that helps customers get the most for their money. ProtoCAM’s engineers may find a better way of orienting the part for production that decreases the cost, and if there is any appearance trade-off in that decision, they can advise on that. Based on how the part or prototype is going to be used, they may be able to recommend a less expensive way to build it. If the customer is not in a hurry, ProtoCAM may be able to schedule the production of the part at a less busy time to provide cost savings.

On the other hand, ProtoCAM is perfectly willing to provide premium rapid prototyping services when needed by customers, offering quick turn production and special handling when the customer needs it. The key is that ProtoCAM can match our customers’ needs across the board - for quickness, budget and special handling - on any job.

To get a good rapid prototyping price quotation, please complete our Request for Rapid Prototype Quote form, upload your 3D CAD file(s) and provide as much information as possible about the part and how it will be used. The more information you provide, the better we are able to respond to your request with a competitive price quote.

Rapid Prototype Quotes - Getting a Quote for a Prototype / Part | #2 in FAQs Series

2011-12-20T13:51:00.000-05:00

This is the second in a series of FAQs - Frequently Asked Questions - that ProtoCAM hears from customers who call or email. Topic #2 concerns getting a quote for a prototype / part, including:

How do I get a quote from ProtoCAM?
How long will it take to get a quote
Why doesn’t ProtoCAM use instant online quoting?

(Note - we hear people refer to the item they want quoted as both a part and a prototype; we’ll call it a part in this blog post.)

To provide you with an accurate price quotation for the parts you want us to make, we ask customers to complete the Request for Rapid Prototype Quote form on our website. This provides you with the opportunity to upload your 3D CAD file and provide additional information about the part’s specifications and how it will be used. The more information you provide, the better we are able to address your request.

Our engineers work on quotes between 7:00 AM and 5:00 PM Eastern Standard Time Monday through Friday, and can generally provide a price quotation in two business hours or less. If it is sent after hours, we’ll work on it first thing in the morning and typically send out your quote by 10 AM. Quotes are normally delivered via email in a PDF file, but if you require something outside of this regular process, just let us know.

ProtoCAM does not use instant online quoting because we believe your request deserves the attention our dedicated engineers offer. We have years of experience providing rapid prototyping services and bring a depth and breadth of technical and practical knowledge that cannot be replicated in a computer-generated quote. Instant online quotes are fast, but may not necessarily be good. We want to understand your part and how it is going to be used so that we can provide you with the best possible solution at the best price. In many cases, we can apply our expertise to find better and possibly less expensive ways to make your part.

Rapid prototype quotes FAQ summary:

How do I get a quote from ProtoCAM? Answer: Use the Request for Rapid Prototype Quote form
How long will it take to get a quote? Answer: Usually a couple of hours
Why doesn’t ProtoCAM use instant online quoting? Answer: ProtoCAM can do it better with people providing your quote!

File Types for Rapid Prototyping/Additive Manufacturing Quotes | #1 in FAQs Series

2011-11-21T11:24:00.001-05:00

This is the first in a series of FAQs - Frequently Asked Questions - that ProtoCAM hears from customer who call or email. The topic - File Types!

A critical part of any interaction with ProtoCAM is the file that is sent to us containing the representation of the part or prototype to be produced. Getting this handshake - the exchange of the 3D CAD file - accomplished smoothly is a good first step that allows us to review the part quickly and process your request for quote or questions in the shortest time possible.

Here are some typical questions we hear, and our best responses:

What File Formats do we prefer?

ProtoCAM easily accepts any of the following file formats:

STL files - STL is a file format native to the stereolithography CAD software created by 3D Systems. File extension: *.stl
Native Pro/E files - from Pro/ENGINEER. File extensions: *.prt, *.prt.*, *.xpr
Native SolidWorks files - SolidWorks is a 3D mechanical CAD (computer-aided design) program from Dassault Systèmes SolidWorks Corp. File extensions: *.sldprt, *.sldasm, *.slddrw
Parasolid files - Parasolid is a geometric modeling software from Siemens PLM Software used in many CAD/CAM packages. File extensions: *.x_t, *.x_b
STEP files - ISO 10303 is an ISO standard for the computer-interpretable representation and exchange of product manufacturing information. It is known informally as "STEP", which stands for "Standard for the Exchange of Product model data". File extensions: *.stp, *.step
IGES files - an Initial Graphics Exchange Specification is a file format which defines a vendor neutral data format that allows the digital exchange of information among CAD systems. File extensions: *.iges

(Sources: various pages on Wikipedia, 10/25/2011)

Other file types may be acceptable - contact ProtoCAM and our engineers will verify.

What Settings Should I use when exporting an STL file?

ProtoCAM’s preference would be that you to export a binary file using the highest resolution setting your CAD package will allow. If this results in an abnormally large file size or if you cannot get the desired resolution, you can submit one of the other preferred file formats for ProtoCAM to translate.

What is the best way for me to send you my files?

Use the file upload feature in ProtoCAM’s Request a Quote form. If the file is unusually large or there are other extenuating circumstances, check our alternative file transfer instructions or contact ProtoCAM to make other file transfer arrangements.

ProtoCAM- Defining Excellence in Rapid Prototyping

2011-11-14T14:41:00.001-05:00

"What's in a name? That which we call a rose by any other name would still smell as sweet."

-William Shakespeare

A few days ago, a customer wrote us with a compliment stating-
"You guys put the PRO in ProtoCAM."

While hearing words of gratitude from our customers about our rapid prototyping services is always poetry to our ears, this time it also provided the impetus to reflect on what our name means to us as a company, and the message it may convey to others.

Let's take a brief glance at Dictionary.com to explore the etymology of the underlying components, shall we?

proto-
a combining form meaning “first,” “foremost,” “earliest form of,” used in the formation of compound words (protomartyr; protolithic; protoplasm), specialized in chemical terminology to denote the first of a series of compounds, or the one containing the minimum amount of an element.
Also, especially before a vowel, prot-.
Origin: < Greek, combining form representing prôtos first, superlative formed from pró; see pro-2

CAM
[kam] noun
computer-aided manufacturing.
Origin: 1965–70

Fun! So ProtoCAM literally translated means something like "The foremost in computer-aided manufacturing." Interesting how the origins of the components of our company name describe not only the product, but the process- futuristic technology like lasers and 3D computer modeling, finished with classic skills and craftsmanship to produce prototypes of tomorrow's products.

Initially we developed the company name simply to identify ourselves as creating Prototypes through Computer Aided Manufacturing. Though it certainly describes our field, we work hard to make sure the more literal interpretation applies as well. We differentiate ourselves by providing exceptionally high quality prototypes on very tight schedules. Our daily efforts to truly provide "Excellence in Rapid Prototyping" have helped earn us the distinction of being the Eastern United States' largest rapid prototyping bureau.

But soft! What light through yonder window breaks? It is a laser, and builds a 3D part in a vat of ultra-violet sensitive resin!

Next time you need a high quality prototype rapidly, remember the PROs at ProtoCAM! (as for prose, well, the library is probably a better bet!)

Green manufacturing at ProtoCAM

2011-11-08T10:34:00.000-05:00

Recently, ProtoCAM adopted a more environmentally friendly, renewable material to replace packing peanuts- Expandos. If you've not yet received a shipment from us with them, below is a brief run-down of some of its qualities we've appreciated.

Primarily, it squarely addresses the fundamental principals of environmental friendliness- Reduce, Reuse, Recycle.

Reduce-
Similar to Ikea, the packing is sent to us flat, then built into its final state in our office. It comes in bundles of 8"x12"x19" (think breadbox) and expands to 25 cubic feet (think refrigerator.) In addition to reducing the frequency of inbound packaging material shipments, we're able to store weeks of supplies in a smaller space.

By virtue of their triangular shape and jagged edges, the individual pieces lock to one another to hold parts in place, and they are much more resistant to crushing than peanuts. The result is- instead of sifting to the bottom, as heavier objects tend to do during shipping in peanuts, the parts are suspended where they are packed. For many items, this allows us to safely protect parts without the extra time and material needed to cut foam packaging specific to the individual part. For our customers, this means less waste, and greater flexibility to reuse the packaging material we send.

Reuse-
Customers can enjoy some of the same benefits we've enjoyed as they re-use the packaging for their outbound shipments. Of course, that can be done with other packaging as well, and while we no longer purchase any packing peanuts, we do reuse those sent to us rather than sending them to landfills.

Recycle-
Not only are they made from recycled materials, they are extremely easy to recycle. For customers who do no shipping or can't reuse them for some reason, Expandos can go right into the recycle bin. They're made from what's basically a heavy card-stock, so they can be recycled along with the paper in most offices.

A few customer comments-
"By the way, the new packing material is cool stuff."
"The packing material is interesting. Have not seen it before."
"It is nice because it does not stick to the items or myself."
"No objections to it at all. Seems to do the job just fine."
"Not as messy."

Like our customers, we love that unlike peanuts they don't blow around, and no more annoying static cling! We're not paid spokes-people for the product, and get no benefit from touting its virtues. We're just very excited at the benefits we've gained from switching, and are happy to ship parts to our customers in packing that's more protective, more convenient AND more environmentally friendly.

Stereolithography bones, medical prototyping, and other scary cool stuff!

2011-10-28T09:22:00.000-04:00

No need to wrestle zombies, dismantle skeletons, or dig through graveyards for bones this Halloween, ProtoCAM has you covered!

As depicted in the video above, additive manufacturing can be a great way to simultaneously produce multiple copies of the same or disparate parts while saving the time and expense of individual tooling.

ProtoCAM can create whole batches of almost any part for prototyping, medical appliance testing, sales demos, or just to have a bunch of cool looking bones! We regularly make stereolithography and urethane castings of bones and other body parts for a variety of medical sales and research purposes. Additionally, our urethane casting processes can produce clarity on par with acrylic and glass.

Wandering the office with a camera is bound to catch a few other scary sights as well. Bones, clear and otherwise, huge spiders, medieval torture devices, and ghouls lurk around every corner!

Happy Halloween!
The ProtoCAM crew

Rapid Prototyping RFQ Cheat Sheet

2011-09-26T13:53:00.000-04:00

Homecoming is over, time to get serious about homework. These tips should help you get your Request For Quote homework done to ensure a rapid and accurate reply with a quote, and get your prototypes how and when you want them.

* Make sure your 3D CAD file is as you want it prototyped; we'll build it exactly how you send it to us. If you have questions, our engineers can help get your project to a build-ready state.
* Compress and combine your files using WinZip or similar compression application
* Submit your request via our online form. Remember, you can upload a compressed file with all your parts and indicate individual quantities, finishes and even materials in the comments section.
* Alternately, you can submit your request using our YouSend It account; this option allows for files up to 2GB. Please make sure to include a detailed description of your desired quantity, material and finish, And as always, please compress and combine your files.

* Homework Hotline: 610-261-9010- Remember, we're always happy to help if you need suggestions on how we can produce the best possible prototypes for you. We're here to help you get it right the first time instead of incurring the delays and expense of having to re-submit. Our skilled engineers are available Monday through Friday, 8am-5pm Eastern time.

We're here to help you achieve Excellence in Rapid Prototyping!

PolyJet Cheat Sheet

2011-09-19T11:31:00.002-04:00

This week, we have a bonus cheatsheet on PolyJet; RFQ homework tips coming soon.

One of the most useful features of PolyJet is the ability to create a wide range of part attributes with different mixtures of the digital material. Tango Black can be soft and rubber-like all the way to Vera White which is similar to hard plastic, and most options in between. Additionally, it can be over-molded to make parts with different characteristics in different areas.

A rundown of properties for a few of the many PolyJet materials ProtoCAM offers:

Tango Black- soft, flexible
Vera White- hard, rigid
ABS-like- as stated, it's like ABS
One datasheet, tons of PolyJet info

For more info, please check the extensive datasheet linked above. As always, we're ready to help if you would like any additional tutelage in determining the best material for your particular prototype.

RTV Molding for Urethane - Go IronPigs!

2011-09-15T14:58:00.004-04:00

With ProtoCAM's hometown team the Lehigh Valley IronPigs in the playoffs, Pig fever has risen to an even HIGHER pitch around the Lehigh Valley.

As you can see, some of the ProtoCAM crew is sporting IronPig colors to celebrate tonight's playoff game. (but not our adamant Steeler's fan. There's one in every crowd!) Our team's families are also getting behind the Pigs. The images below are of a pig's head created in clay, molded in RTV, then shot in urethane by one of our office munchkins.

RTV stands for Room Temperature Vulcanization. It's a process we use to create durable urethane prototypes and short-run production castings of parts. Below are some of the basic steps:

* Create object. Most of our molds are created from SLA prototypes built here at ProtoCAM. We can also mold and reproduce customer-supplied objects.
* Engineer any modifications to allow good mold. Fortunately, our RTV materials allow for some undercuts, pockets and hollow areas. When necessary, our engineering team can advise on modifications to create the best results.
* Mix RTV molding material. We typically use specially formulated silicone based platinum molding compounds. It molds very well, and offers extremely accurate molds with great properties.
* Pour the mold. Once the piece is positioned in its box and mold release is applied, RTV material is carefully poured around the object to ensure all surfaces are covered with no voids.
* Remove object. After a few hours the RTV is cured; most objects are cut from their molds, while some molds are cast in multiple parts and can simply be pulled apart.
* Shoot urethane. Urethane is mixed to specification, degassed, and typically shot into mold under vacuum to ensure flawless final pieces.

Most molds can be used to create approximately 25 final pieces. Depending on production material, object surface, and undercuts, the number may vary considerably. Notice the difficulty removing the final urethane IronPig in the video. It's a great job for a 9 year old, but our experienced mold makers would likely have designed the pour and cuts to facilitate easier release.

As always, ProtoCAM's experienced and courteous professionals are here to help you with all your prototyping needs.

GO PIGS!!

SLS Materials Cheat Sheet

2011-09-12T10:37:00.000-04:00

School's in full swing, activities are ramping up, and things are starting to get hectic. To help conserve some of your valuable time, below is a quick run-down of materials to use with your SLS prototypes.

Some of the most popular SLS materials:

*DuraForm PA- durable, forgiving, snap fits
*DuraForm EX- more flexible, strap and living hinges
*DuraForm GF- glass filled, stronger and lighter
*LaserForm A6- metal and tooling

For more info, each description links to its datasheet. As always, we're ready to help if you would like any additional tutelage in determining the best material for your particular prototype.

Next week- study tips to help facilitate completion of your RFQ homework!

SLA Materials Cheat Sheet

2011-09-06T14:04:00.002-04:00

It's that time of year again- summer is unofficially over, time to put away the white shoes, and the kids have returned to school.

For those of us not quite ready to read through the entire text books, below are some crib notes on SLA materials.

*Accura 25- white, ABS-like, a little flex
*Accura 60- clear, hard, good for large parts
*Watershed 1112- ultra accurate builds, can be made nearly glass-like

For more info, each description links to its datasheet. As always, we're ready to help if you would like any additional tutelage in determining the best material for your particular prototype.

Next week's cheatsheet- SLS materials!

Green Rapid Prototyping

2011-08-01T11:23:00.012-04:00

In reading a recent Time Compression article called 'Sustainable Development: Green is Good' (sub-titled: Why waste? Product and process development done right can be beneficial—socially, environmentally, and economically. A triple win.), it become obvious - rapid prototyping has always been a green technology!

1. Rapid prototyping inherently is a green technology as it is an additive process where no material is wasted in constructing the part layer by layer. Compared this additive fabrication process to subtractive operations - where all removed material is likely to be wasted
where nothing is wasted - and it's easy to see that rapid prototyping is uses less material.

2. Rapid prototyping (and additive manufacturing to create final production parts) doesn’t require tooling, which also means that less material and fewer resources are used in the manufacturing process.

3. Rapid prototyping is green because it streamlines the product development process so resources of all kinds aren't wasted, including human resources, energy, time and money.

So it's easy to see that rapid prototyping and additive manufacturing are green!

ProtoCAM offers many different "green" rapid prototyping services and environmentally-friendly additive manufacturing technologies; please contact ProtoCAM to discuss your project.

Laser Sintering with LaserForm A6 a Hot Topic at D2P Tradeshow

2011-05-02T09:09:00.003-04:00

LaserForm™ A6 metal laser sintering was a hot topic at the recent Design 2 Part trade show held April 13 and 14 at the Greater Philadelphia Expo Center in Phoenixville PA. Many potential customers expressed interest in the Selective Laser Sintering (SLS) process using the LaserForm A6 steel material. Visitors who came to see ProtoCAM for our rapid metal castings got to see examples of those metal prototypes, but also left the booth with updated information on metal additive manufacturing.

Discussing the process with a well known safety equipment manufacturer, he could not believe that SLS could build such complex geometries in as little as 5 business days. He currently outsources his prototypes to a production machine shop. The downfall is waiting 4 weeks to receive the prototype, and only then can they begin testing. When you know you will have multiple design iterations, having to wait 4 weeks to begin is valuable time lost. Using the SLS metal additive manufacturing process allows multiple designs to be evaluated in the same time frame for one design - a real competitive edge for fast time-to-market!

Keep in mind that there are certain limitations with the process, but the engineers at ProtoCAM can provide the expertise to guide you through the process and make recommendations so your prototypes are done quickly and meet your specific needs.

ProtoCAM offers many different rapid prototyping services and additive manufacturing technologies, including metal laser sintering using LaserForm A6. Please contact ProtoCAM to discuss your application or with any questions about LaserForm™ A6, metal prototypes and metal parts.

Photo taken from 3D Systems' LaserForm™ A6 data sheet.

Prescription Bottle Prototype, Colored Bottle Prototyping

2011-01-24T00:09:00.006-05:00

photo © 2006 Bart | more info (via: Wylio)A while back ProtoCAM worked on a project to create a new prescription bottle that is now being used for prescriptions dispensed by a major retailer. ProtoCAM created the colored prescription bottle prototype for the plastic bottle manufacturer.

Dyed Prototype Bottle
A key aspect of the prototype was its red color, a departure from the traditional amber color of prescription bottle. The red color matched the retailer’s brand and conveys the notion of caution. So even with its non-traditional shape, it would be recognized as a prescription bottle.

ProtoCAM made the stereolithography prototype using Accura 60, a high-clarity SLA material. But a clear prototype prescription bottle would not have provided the visual perception as a prescription bottle; it needed to be red.

ProtoCAM is an expert at dyeing prototypes, and ProtoCAM’s ability to tint this SLA bottle prototype was a key to this project. Using ProtoCAM’s propriety tinting process, the SLA prototype was dyed red and the prototype prescription bottle was given an added dose of realism. As is typical in a new product design cycle, ProtoCAM made several renditions with modifications until the design process was complete.

See more details on coloring prototypes from a previous blog post.

New Prescription Bottle Design
This new prescription bottle boasts a revolutionary design and was recognized with a Gold “Design of the Decade” award from the Industrial Designers Society of America (IDSA) for Solution to a Consumer Problem. The design demonstrates a completely new approach to usability, literally turning the prescription bottle industry upside down. Its practical impact is to reduce user errors with prescriptions. This new prescription bottle was released and is used by a major retailer and its share of the prescription market has increased significantly since its introduction. ProtoCAM is proud to have played a part in this project.

Contact Us to inquire about how ProtoCAM can help with creating your bottle prototype or colored prototype. ProtoCAM is ready to provide a quote for your colored bottle prototype or related projects.

ABS Prototypes, ABS Rapid Prototyping

2011-01-12T18:34:00.007-05:00

ProtoCAM’s customers sometimes request an "ABS prototype". ABS is a commonly used plastic and the acronym ABS is used almost always instead of the long name: Acrylonitrile Butadiene Styrene. According to MatWeb,

ABS is a copolymer of Acrylonitrile, Butadiene, and Styrene. ABS plastics generally possess medium strength and performance and medium cost; ABS is often used as the cost and performance dividing line between standard plastics (PVC, polyethylene, polystyrene, etc.) and engineering plastics (acrylic, nylon, acetal, etc.)

Some customers know from experience or their requirements that they want a prototype made from ABS. The question that needs to be asked is: Does the part need to truly be ABS?

The only way to generate an ABS prototype is to have it made using the FDM process. The parts are made of ABS plastic and have 90% of the properties that an injection molded ABS would have. The downside to FDM prototypes is the rough surface finish that is achieved due to the process.

ProtoCAM offers other options depending on your requirements to achieve an ABS-like prototype. If you want fast turnaround, good aesthetics and improved part accuracy, an SLA prototype can sometimes be used to represent an ABS part. The mechanical properties are not as good, but the aesthetics and dimensional accuracy are excellent.

If you need the best of both worlds - aesthetics and strength - the best solution is to generate an RTV mold and cast urethane parts. Cast urethanes can match the properties of ABS and also look, feel, and act the part. Cast urethanes can be colored with pigment and create a prototype that mimics the quality of an injection molded part.

Sometimes the term 'ABS prototype' is just used to mean a prototype for a plastic part. Whatever your needs, ProtoCAM can help to achieve the best results for your project.

ProtoCAM will supply prototype engineering advice as needed so that you get the right prototype for your application. Such recommendations are always specific to the users’ needs. But in general, these guidelines typically apply:

FDM ABS prototypes offer good mechanical properties but lack aesthetics
SLA parts can mimic the look and quality of an ABS part, but do not match the mechanical properties
RTV molded cast urethanes can match both aesthetics and mechanical properties of an ABS-like prototype

ProtoCAM's LinkedIn Profile

2010-11-10T18:33:00.003-05:00

ProtoCAM has updated its company profile on LinkedIn with summary information about some top rapid prototyping service offerings. Check it out! (Note: sign in to LinkedIn required to view.)

Enthusiasm for 3D Printing and 3D Modeling

2010-09-21T12:08:00.005-04:00

Last week the New York Times had a front page article on 3-D Printing Spurs a Manufacturing Revolution describing how 3D printing continues to gain in popularity and some of its uses.

ProtoCAM’s Managing Partner Ray Biery comments:

Regarding this article, I've read numerous similar articles and the enthusiasm for 3D printing technology is terrific. I am thrilled that people are applying 3D CAD modeling and 3D printing to a variety of applications. The key to all of these applications is the material being used. All these rapid prototyping technologies have their limitations in the materials being used as well as the accuracy of the final item printed. Much has been accomplished in the last 10 years, but there is still a lot of work that needs to be done.

But the real fact is that for the most part, the materials that are used in mass production are a "lot better" than you can presently get from 3D printing technologies. Additionally, do-it-yourself 3D modeling - the idea of just sitting at a computer and designing your own refrigerator or anything of substance - is still a little farfetched. First of all, most 3D CAD systems are not really that intuitive. 3D modelers have to understand a fair amount of modeling techniques and design geometry. Second, some mechanical engineering expertise is required. Sometimes a fillet, gusset or radius will mean the difference between success and failure of the design and that type of expertise is not gained without experience.

All that being said, I'm glad that people are aware that 3D printing is getting people to stretch their imaginations and move towards the notion of designing parts themselves. And when do-it-yourself is not an option or when you need professionals experienced in 3D modeling and rapid prototyping materials, ProtoCAM is here to help.

Contact Us to inquire about how ProtoCAM can help with 3D printing, 3D CAD modeling, to print your prototype/part or to request a quotation.

Meadowlands Expo Center Trade Show

2010-09-09T12:40:00.002-04:00

ProtoCAM will be exhibiting at the next Design2Part show: Meadowlands Expo Center in Secaucus, NJ - September 28-29, 2010 in Booth 232.

Would you like to schedule a meeting with ProtoCAM at the upcoming trade show to discuss our rapid prototyping services? If so, please contact ProtoCAM at 610-261-9010 or use our convenient Information Request form - please note in the Comment section that you would like to schedule a meeting.

Bring your ideas for our engineers and they can help you decide the best route for your project.

If you would like to contact us, please call 610-261-9010 or fill out a contact form on our website