Brainstorm: Rapid Prototyping Materials (Part 3)

The prototyping that works as fast as the imagination

In the Product Design & Development Brainstorm we talk with industry leaders to get their perspective on issues critical to the design engineering marketplace. In this issue, we ask:

What are the newest advancements in rapid prototyping materials? What are your expectations for future materials?

Advances in rapid prototyping materials include improvements in tear and thermal resistance, shape memory, stiffness, and photorealistic color.

In terms of composite printing, 3D Systems has announced a new elastomer material, with up to 700% elongation, low Shore A value of 30, enhanced tear resistance, and excellent shape memory.

READ: Brainstorm: Rapid Prototyping Materials

This material can run in tandem with ABS-like or Polycarbonate-like rigid materials to produce 14 functional material composites with unique and specific physical properties. This material features exceptional toughness in single print jobs or as individual features on a single part.

To suit the toughest, most demanding end use and functional prototyping applications, a new selective laser sintering (SLS) composite material uses both glass and aluminum. The glass filled nylon print material offers maximum stiffness and elevated thermal resistance for applications that require the minimum material flexibility and higher temperature environments or exposures.

The aluminum nylon print material has a high strength-to-weight ratio and enhanced thermal resistance for demanding applications where rigid articles are required, but weight reduction is desired, such as automotive and aircraft parts.

3D Systems has also developed a wax resin hybrid casting material to be used on the ProJet 1200 micro-SLA printer. This material enables non-technical direct investment casting using the same investment materials as common lost-wax casting, for parts such as jewelry and small medical devices.

READ: Brainstorm: Rapid Prototyping Materials (Part 2)

Also, new materials are printing jewelry mock-ups or counter-top samples without the expense of precious metals and casting, and a new clear material ideal for samples and prototyping.

Additionally, new plastic-based powder and color binders for the ProJet 4500 and ColorJet Printers provide vivid, photorealistic color in a light-weight and durable plastic. This allows for the full color printing of parts with delicate features.

Expectations for future materials include: faster imaging materials, closing the gap between conventional injection molding processes, improved mechanical properties and surface finishes, and long term stability. Additionally, it would be great to see expanded properties to enable new applications.