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Additive Manufacturing vs. Rapid Prototyping: Understanding the Differences

Additive Manufacturing and Rapid Prototyping are two terms that are often used interchangeably. However, these two technologies are unique in their own ways. Despite their similar uses, working principles and the end results, these technologies are different in various aspects. This post will explore the differences between these two technologies and their applications.

Additive Manufacturing (AM)

Additive manufacturing refers to a process whereby a 3D model is created by layering material gradually. This means that parts are produced through an additive process, in contrast to subtractive manufacturing that removes material to achieve the desired shape. In an AM process, a 3D model is first designed using Computer-Aided Design (CAD) software, followed by 3D printing the object using specialized printers.

AM has a broad range of applications, including aerospace, healthcare, automotive, and the military, among others. This technology can produce parts with intricate geometries and high precision, which makes it a suitable option for fabricating complex parts.

Rapid Prototyping (RP)

Rapid Prototyping, also called 3D printing, is a manufacturing technology that involves the creation of physical models from 3D digital data. The technology uses an additive process where successive layers of the material are deposited to form a 3D object. Like AM, RP starts with a 3D model created through CAD software and fed into a 3D printer.

RP technology is commonly used in various industries such as healthcare, automotive, architecture, and consumer products. Its use is expanding in the engineering and design sectors, where it is used mainly for prototyping and testing. RP technologies have made many designers and engineers move from using traditional prototyping methods like CNC machining to make parts.

Differences between Additive Manufacturing and Rapid Prototyping

The primary difference between AM and RP is the range of parts they can produce. Additive manufacturing is an umbrella term for a range of manufacturing processes that produces final parts, including Direct Metal Laser Sintering (DMLS), Stereolithography (SLA) and Fused Deposition Modeling (FDM). AM can produce functional parts that can withstand real application conditions. On the other hand, RP mostly involves printing prototypes for visualization and testing.

In terms of speed, RP is faster than AM since it usually involves the printing of prototypes only. AM works by producing the end-use parts, making it a more extended process.

Another factor that differentiates these two technologies is the materials they use. Additive manufacturing uses a vast range of materials from plastics, metals, ceramics, and composites. RP, on the other hand, uses materials such as photopolymer, which is a type of resin. This makes it difficult to use for fabrication of functional parts.

Conclusions

Additive manufacturing and Rapid Prototyping are often used interchangeably, yet there are fundamental differences between the two technologies. AM produces functional and complex parts that can withstand the harsh application conditions, while RP mostly produces prototypes for visualization and testing. So, for the creation of a model or a prototype, RP technology comes in handy, while for a final product or parts that support real-life applications, AM is the go-to technology.

how does additive manufacturing differ from rapid prototyping

On-demand Rapid Injection Molding

Sigma’s rapid tooling service helps you to have the low volume to large volume plastic parts done, with no compromise on the material selection.

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Our rapid injection molding Application

Sigma Technik Limited's rapid injection molding service injects molten plastic materials into molds using injection molding machines and molds, and cools and solidifies them over a certain period of time, ultimately forming the required plastic parts. This manufacturing process is usually suitable for producing small and medium-sized plastic parts, which can obtain high-quality and precise parts in a short period of time.

Plastic Injection Molding

Injection molding is a common manufacturing process to produce low volume to large volumes of parts typically made out of plastic. The process involves injecting molten material into a mold and letting it cool to a solid-state.

Liquid Silicone Rubber Molding

Liquid Silicone Rubber is known as LSR, which is a process used to produce parts made from silicone rubber, widely used create products such as medical devices, automotive parts, baby care products, and many others.

2K Injection molding

2K injection molding is a manufacturing process in which two different types of plastic materials are molded together in a single operation to create a single homogeneous component. This process allows for efficient and cost-effective production of high-quality parts that can perform unique functions.

Overmolding and Insert Molding

Overmolding / Insert molding combines two or more materials into a single part, one of the material is usually soft and flexible, or metal. The purpose of overmolding/insert molding is to add functionality, improve grip, provide protection, or enhance aesthetics.

Mission And Vision

Rapid injection molding materials

ABS

ABS is a type of plastic with high strength, hardness, and toughness. It has good impact resistance and wear resistance, and is suitable for manufacturing shells, components, and models.

PC

PC is a transparent, high-strength, high-temperature resistant, and excellent electrical insulation material. It is suitable for manufacturing transparent components, electronic components, and automotive components.

PP

PP is a relatively flexible material with excellent corrosion resistance and high temperature resistance. It is suitable for manufacturing containers, pipelines, baby bottles, etc.

PA

PA is a material with high strength, high rigidity, and wear resistance. It is suitable for manufacturing gears, bearings, brackets, etc.

POM

POM is a material with excellent wear resistance, toughness, and rigidity. It is suitable for manufacturing gears, bearings, pulleys, etc.

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What can we do?

Sigma Technik Limited, as a prototype production company and rapid manufacturer focusing on rapid prototyping and low volume production of plastic and metal parts, has advanced manufacturing technology, one-stop service, diversified manufacturing methods, on-demand manufacturing services and efficient manufacturing processes, which can provide customers with high-quality, efficient and customized product manufacturing services and help customers improve product quality and market competitiveness.

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Rapid Injection Molding FAQs

Burrs appear on the surface of the product, which affects its aesthetics and safety. The solution can be to adjust the parameters of the injection molding machine, such as temperature, pressure, speed, etc., or to perform post-processing, such as polishing, sandblasting, etc.

The warping deformation of the product is usually caused by unstable parameters such as temperature and pressure of the injection molding machine, or improper mold design. The solution can be to adjust parameters such as temperature and pressure, or to redesign the mold.

The occurrence of bubbles inside the product may be due to the high temperature of the injection molding machine and the high moisture content of the material. The solution can be to reduce the temperature of the injection molding machine, adjust the water content of the material, increase the pressure of the injection molding machine, etc.

The product size deviation is too large, which may be caused by material thermal expansion, mold deformation and other reasons. The solution can be to adjust parameters and optimize mold design based on material characteristics.