Rapid prototyping and 3d printing

Rapid prototyping and 3d printing

Nov 25, 2023 | News Prosilas

The first physical output of a project

Rapid prototyping constitutes the initial phase of the physical production of a project, leveraging advanced technologies such as 3D printing.

Prosilas stands out as a leader in the field of rapid prototyping and additive manufacturing for over twenty years.

Prosilas stampe tridimensionali in carbonmide per prototipi rapidi

Photo courtesy : Bimota 

Photo courtesy : Armotia

Prototype: Definition and Utility

A prototype is the physical realization of an idea or project, an initial model created to evaluate both the aesthetic and functional aspects of an application.

What is Rapid Prototyping?

Rapid prototyping is the process of quickly creating a physical model of an idea or project.

This model, called a prototype, provides a tangible and visual representation of the application in the development phase. 3D printing has become a key technology for rapid prototyping due to its ability to rapidly translate digital designs into physical objects.

The primary purpose is to expedite the development process, enabling a comprehensive assessment of the performance and form of the product.

In Which Cases to Use Rapid Prototyping?

It is particularly useful in the early stages of designing and developing new products.

It is ideal when there is a need to quickly assess aesthetic aspects, optimize geometries, improve production cycles, and evaluate functional aspects.

Furthermore, it is valuable when exploring different iterations of a design without having to invest in expensive molds.

Un serbatoio funzionale realizzato con il materiale PA2200/poliammide, inizialmente progettato come prototipo per test di laboratorio e collaudi, è stato successivamente incorporato nel processo di produzione. La sua progettazione mirata lo rende adatto per il sicuro contenimento di liquidi corrosivi come benzina, gasolio, liquido glicole-etilenico, liquido freni e ATF.
Story of success of a 3D tank

Advantages

  • Reduction of Development and Production Times: 3D printing allows for the rapid translation of designs into physical prototypes, significantly reducing development times.
  • Cost Reduction: By eliminating the need for expensive molds, rapid prototyping with 3D printing helps contain costs in the design and development phase.
  • Improvement of Product Quality: The ability to assess aesthetic and functional aspects in an early phase enables continuous improvements to the final product’s quality.
  • Production Evaluation: With the initial step of prototyping, subsequent steps for mass production can be evaluated, allowing assessments of timelines and costs.

3D Printing Technologies for Rapid Prototyping:

There are various 3D printing technologies suitable for this service.

Among these, SLS (Selective Laser Sintering) and SLA (Stereolithography) are often used for creating prototypes with precise details.

Other approaches, such as using filaments or metal powders, offer different options based on the project’s requirements.

We provide our technological offerings based on project needs and assist the client in choosing the best solution.

Our capabilities

Photo courtesy : Bimota 

Case History Bimota

Bimota utilizes rapid prototyping in collaboration with Prosilas to expedite the development of its new motorcycle models.

Thanks to 3D printing, the design and testing process has become more efficient, reducing the time required to transition from the idea to the prototype from approximately 12 to 4 months.

Read the Case History
Dimensional Tolerances

Dimensional Tolerances

Nov 20, 2023 | News Prosilas

Tips & Tricks: What are Dimensional Tolerances?

Dimensional Tolerance in SLS 3D Printing: Management and Control by Prosilas

 

 

Dimensional Tolerances

3D printing has revolutionized the way products and components are manufactured, offering unprecedented flexibility and customization.

Even in this innovative technology, dimensional precision is a crucial aspect, and Selective Laser Sintering (SLS) stands out for its ability to produce parts with remarkable precision.

Dimensional tolerance refers to the possible deviation within which the printed part can vary from the original geometry.

Specifically, we are talking about +/- 0.3 millimeters for parts up to 100mm and +/- 0.3% for larger dimensions.

Watch the full video

Photo courtesy Protototal Industries

Thermal Expansion

This difference between the nominal dimensions in the 3D file and the printed part is due to thermal expansion, an intrinsic phenomenon in SLS technology.

This printing methodology involves heating the materials to their melting temperature, such as 170°C in the case of polyamide.

During the subsequent cooling process, the part transitions from the melting temperature to room temperature, contracting by approximately 3%.

Our Approach

The parts are initially processed with larger dimensions, using scaling factors specific to each machine and material.

The determination of these factors occurs through the periodic production of samples, a practice that allows monitoring and maintaining control over the dimensional tolerances declared to customers

L'approccio di Prosilas consiste nel produrre parti inizialmente con dimensioni maggiori, utilizzando fattori di scalatura specifici per ciascuna macchina e materiale.

To achieve the highest level of precision, we incorporate this element during the job preparation stage.

Quality Standards

Thermal shrinkage is not entirely constant; hence, an average of the results is calculated and applied.  This phenomenon can vary depending on various parameters, such as cooling times, part orientation, shape, and thickness.

To ensure maximum precision, we integrate this aspect during the job preparation phase. Geometries are carefully modified in the software, taking into account the inevitable dimensional variations that occur during material cooling.

This proactive practice demonstrates our commitment to providing 3D-printed components that strictly meet the quality standards required by our customers.

Per garantire il massimo della precisione, integriamo questo aspetto durante la fase di preparazione dei job.

The software undergoes meticulous modifications to the geometries, considering the inevitable dimensional variations occurring as the material cools.

What are the NDAs?

What are the NDAs?

Oct 18, 2023 | News Prosilas

NDA: The Value of Confidentiality Agreements at the Heart of a Trust Relationship Between Service Providers and Manufacturing Companies

Confidentiality Agreements, commonly known as NDAs (Non-Disclosure Agreements), are legally significant in the manufacturing industry as they are designed to protect confidential and sensitive information.

NDA contracts are widely used in both the industrial and technological sectors, as well as in research and development, with the explicit goal of preventing the disclosure of sensitive data to third parties without the explicit consent of the information owner.

Managing Industrial Secrets at Prosilas

Prosilas works closely with companies, contributing to the development of projects intended to launch in the market within the next three years. In this context, safeguarding information plays a critical role.

Therefore, we provide support for both prototype component production and mass production, utilizing a comprehensive range of technologies, ranging from complex additive manufacturing and 3D printing methodologies to more traditional injection molding techniques.

Watch the full video

Within the Prototal Industries group, we have privileged access to diverse technological resources, occasionally collaborating with external suppliers. This is precisely why it is crucial to extend confidentiality throughout the production chain when exchanging information with colleagues and partners.

 

Cybersecurity: Protecting Information Online

Information communication occurs through digital platforms or by transmitting files via email, emphasizing the relevance of cybersecurity issues.

In this regard, Prosilas consistently invests in enhancing its cybersecurity systems, ensuring adequate monitoring and protection of exchanged information.

Our staff also undergoes continuous specialized training to maintain high-level expertise in this field.

Dedicated Spaces: Protecting “Offline” Projects

Confidentiality is a fundamental pillar of our operations and is ensured through the use of NDAs. However, there are circumstances where a higher degree of secrecy is required. We have dedicated specific spaces within our laboratories, providing access exclusively to authorized personnel. Information security is an indisputable priority to preserve the trust and respect of our clients.

 

Workflow in Additive Manufacturing

Workflow in Additive Manufacturing

Sep 10, 2023 | Senza categoria

3D Production: Principles, Rules, and Technologies

Industrial 3D printing has evolved from rapid prototyping to mass production, offering significant advantages to companies: reduced production times and costs, improved product quality, and customization possibilities.

This technology enables the creation of complex components in a single phase, simplifying assembly and allowing greater flexibility in responding to market needs.

Workflow

At the core of conceiving productions through additive manufacturing technologies, fundamental aspects remain tied to the employed technologies, materials used, and the skills of designers and operators.

The intricate workflow characterizing a typical production with industrial 3D printers involves delicate phases that can be challenging to manage for less structured companies or those lacking experience and know-how.

A production process using additive manufacturing technologies can be achieved only through some fundamental stages:

  1. Design and optimization/lightweighting of geometries based on technologies and materials.
  2. Nesting and optimization of production parameters.
  3. Utilization of facilities and technologies with high production capacity.
  4. Application of post-processing technologies (aesthetic and functional).
  5. Quality analysis and repeatability.
  6. Certification of processes and materials.

Design for Additive Manufacturing

Design for Additive, or Design for 3D Printing (DFAM), represents an innovative approach in the design of components and products.

New possibilities emerge in the field of design, enabling the creation of complex shapes and intricate geometries that would be difficult or impossible to achieve with conventional methods.

Design for Additive focuses on maximizing the potential offered by 3D printing, optimizing the internal structure of objects to enhance performance, reduce weight, and minimize material consumption.

Moreover, this methodology allows for greater customization of products, adapting them to the specific needs of the user/client.

A profound understanding of the characteristics of 3D printing and the ability to fully exploit its potential are required to create innovative and efficient solutions.

Nesting

Nesting, a specific technique for the orientation and organization of components in the setting phase of production, is crucial in every additive manufacturing project using 3D printers.

Unlike the production of individual parts, the production of medium to large batches with 3D printing requires a complex optimization process before printing.

Aspects such as orientation study and nesting have a significant impact on the times, quality, and costs of production processes, results achievable only through a deep understanding of processes and manufacturing technologies.

Thanks to the use of dedicated software, accumulated experience, and advanced management and control systems, Prosilas has established itself as one of the leading European players in the field of additive manufacturing for the industry

Technology

Prosilas’ machinery fleet, mainly composed of industrial production systems with SLS (Selective Laser Sintering) technology – 13 industrial Selective Laser Sintering printers, including 6 large-sized ones, has allowed the development of a complete and reliable industrial system capable of meeting customer needs from order reception to part realization and post-processing treatments.

The targeted choices made over the years have positioned Prosilas as one of the few entities capable of successfully operating in additive manufacturing for the industry.

Our technologies

Post-Processing

Prosilas has invested significantly in enhancing the finishing department to deliver customized finished products to customers. Our primary commitment is to find flexible and high-quality post-production solutions that fully meet the aesthetic and functional needs of our clients.

We are continually refining our post-production processes to make them replicable and reliable. We have integrated automated finishes, such as vapor smoothing and coloring, along with manual processes to adapt to the unique specifications of each project.

Alla parte stampata in 3D con il materiale PA2200 viene prima applicato il fondo per rendere liscia la superficie e poi colorato secondo le richieste del cliente.

Quality and Certification

To ensure maximum precision and resolution, Prosilas implements stringent control procedures.

Productions undergo a series of detailed checks using specialized software and state-of-the-art 3D acquisition systems. These advanced tools enable our team to identify any non-conformities between CAD geometries and the physical parts produced through additive manufacturing.

Conformity is at the core of our operations, and our codified and certified procedures constitute a fundamental pillar of an integrated system.

This system is designed to ensure a high standard of quality for every stage of additive production, from the initial design to the final realization. Thanks to this commitment to excellence and our established expertise, Prosilas stands out as one of the few companies capable of providing reliable, repeatable, and certified additive manufacturing services

STL File : the most common errors

STL File : the most common errors

Sep 6, 2023 | News Prosilas

Normal lines inverted, holes and multiple shells

In this article, we will discuss the most common errors found in STL files, which usually involve inverted normals, presence of holes, and multiple shells.

These errors often result from mistakes during part modeling or during the export and conversion process to the STL file format using CAD software. These defects need to be corrected in order for the part to be suitable for printing.

As highlighted in the previous post, the STL file, necessary for 3D printing a part, represents a three-dimensional geometry composed of triangles oriented in space.

Watch the full video

Normal line inverted

Each triangle is described not only by the coordinates of its vertices, but also by the normal, which is a vector perpendicular to the plane on which the triangle is positioned, and its orientation defines the outer side. In some cases, the normal of these triangles can be inverted, mistakenly identifying an outer side as the inner side and vice versa. Such a situation can lead to errors during the printing process.

Example of a normal line inverted 

Example of a normal line corrected

Hole in the STL file

The second most common error encountered is the presence of holes, which can be caused by missing surfaces or misalignment between triangle vertices.

These holes need to be manually corrected if they are of considerable size, or automatically using specialized software if they are smaller. The presence of holes can compromise the quality and functionality of the printed part.

The presence of holes can compromise the quality and the realization of the part printing.

Holes in a STL file

STL file corrected

Shell Multiple

Lastly, we encounter the issue of multiple shells. A shell refers to a group of connected triangles. The presence of multiple shells in a part indicates the presence of separate groups of triangles. In this case, the inner shell overlaps with the outer shell.

Resolving this type of error is necessary to avoid anomalies during the slicing of the model into layers or incorrect surface generation, as well as to prevent printer jams. It is important that all shells are properly joined to achieve a coherent and functional printed part.

This situation can also occur when, in the design phase, the shapes that make up the CAD model are not properly integrated into the rest of the shell, but remain separate.

It is crucial to ensure that all components of the model are correctly integrated into the main shell to avoid printing issues and ensure the quality of the final product.

Example of Multiple shells

Example of Multiple shells

Multple shells fixed 

When we receive the files. stl from our customers, it frequently occurs the need to make changes and corrections before proceeding with the production.

STL correction requires specific skills and the use of dedicated software to repair imperfections and ensure that the part is ready for printing.

Our team is fully committed to making such corrections with the utmost precision and timeliness, in order to ensure that the printed parts reach high quality standards and fully meet customer expectations.