The advent of advanced digital technology has opened up new perspectives in the field of dentistry for design and development. Rapid prototyping is a technique that uses 3D printers or stereolithography devices to create a three-dimensional 3D model of a component or product quickly and automatically. RP has numerous dental uses, such as implant surgical guidance manufacturing, zirconia prosthesis, and metal casting molds, maxillofacial prosthesis and fixed and reversible partial denture structures, dental prosthesis wax patterns, and full denture.
Rapid prototyping provides exciting possibilities, but the method is daunting because it involves a high degree of creative skill, which ensures that dental technicians should be able to work with the models obtained after impression to produce a mirror image and achieve good aesthetics. Rapid prototyping has been a crucial technique for shortening product design and development time. The role of RP in time compression engineering is discussed in this article and a brief overview of three RP processes with the highest commercial effect on the market is given.
Rapid prototyping services offer an array of resources based on a model’s requirements and aspirations. Using 3D printing, a part that is not required to withstand pressure and force can be rendered easily and accurately and is useful for the visualization process of part design and implementation. However, some materials are designed to endure a little more wear and tear as they are checked by engineers to see how the final product blends into other parts of the final product and double-check for flaws. Stereolithography is one method by which engineers generate detailed component models that can be manipulated in much the same way as the final product.
Rapid Prototyping Process
Using quick prototyping to generate parts for component fit and function testing will help to get the product to market quicker than its rivals do. Following the results of their testing and study, changes may be made to design, materials, scale, form, assembly, color, manufacturability, and strength. Many rapid prototyping procedures are open to the product design teams of today. To produce prototypes, some prototyping techniques use conventional manufacturing methods. Other innovations have arisen, and within a relatively short period have been developed. There are hundreds of ways anyone can build prototypes. The product designer is continually trying to decide what process or technology is appropriate for their particular application as prototyping methods continue to evolve.
- Stereolithography: It is an additive manufacturing technique that uses a computer-operated laser to create parts in a pool of UV-curable photopolymer resin. The laser traces and curves a cross-section of the design of the component on the liquid resin’s surface. Just below the surface of the liquid resin, the solidified layer is then lowered and the procedure is repeated. The layer below it is adhered to by every freshly cured layer.
- Direct metal laser sintering: It is a technique of additive manufacture that creates metal prototypes and components of production quality. DMLS uses a laser device that draws on the surface atomized metal powder. The powder is softened to a solid when drawn. After each layer, a blade inserts and repeats the procedure with a fresh powder layer. Most alloys can be manufactured using DMLS, which allows prototypes to work entirely, from the same materials as manufacturing components. If constructed with manufacturing capacity in mind, it also can turn into metal injection molding if necessary, as demand is increased.
- Fused Deposition Modelling: With the use of a computer-controlled print head, the FDM process creates parts from the bottom up. For every cross-section of the desired component, the feedstock for the process is one extruded resin filament that the system selectively reclaims and deposits on the previous layer. The FDM process mainly produces ABS or PC components, so they appear to be stronger than components from other additive processes. The parts, however, are often porous and have a pronounced stair-stepping or rippling texture, especially at layer junctions, on the external finish. With the system, it may also be difficult to reach close tolerances.
- Three-Dimensional Printing: An inkjet print head moves across a powder bed in 3DP, selectively depositing a liquid binding material and repeating the process until the entire part is formed. The unbound powder is removed after completion, leaving the finished piece.
- Poly-JET: It uses inkjet heads to jet a high-resolution UV-curable material into very thin layers. The materials are thrown onto a construction pane, layer for layer in ultra-thin layers until the part is completed. Immediately after tossing, UV light cures per layer of photopolymer. A hand and water jetting, which is specifically designed to support complex geometries, will easily remove the gel-like material.
The development cost is managed by the Rapid Prototyping Method. If individuals have a full preset design of a particular model, they must be able to make a fast estimate to reduce unnecessary costs. To do the correct analysis without reducing the overall output, people can also position this computerized prototype model in a community of product quality analyzers. 3D printing is lifelike and is the nearest version in the minds of model designers. Under different conditions, the rapid prototyping process helps save costs, such as:
- 3D printing provides ample insight into the feasibility of the object, and whether or not one can go ahead with the production process. Thus, the need to build a physical prototype is removed, saving costs.
- The need for product prototype can be dismissed by individuals, as 3D printing reveals if the product looks failure or the concept itself appears unrealistic, which is a real cost saver.
- People should stick to 3D models and evaluate the viability of the product for innovations and inventions where the cost of prototyping is extremely high, or where the product is identical to another product.
- People can have their product printed in 3D and outsource physical prototyping to a service provider at a lower cost than making it in-house, saving time, effort and money.
- By allowing designers to spot bugs during the early stages and make productive improvements in the design process itself, 3D printing reduces cost.