Prototype development is a critical step in bridging the gap between a conceptual design and final production. Particularly in custom roto molding, the ability to swiftly iterate and refine designs through prototyping is invaluable. This is where Fused Deposition Modeling (FDM) technology comes into play. FDM, a form of 3D printing, uses engineering-grade thermoplastics to create highly accurate and functional prototypes that closely mimic the properties of the intended final products. By integrating FDM technology in the prototype development phase, engineers and designers not only enhance the precision of their models but also significantly accelerate the design process.
Understanding FDM Technology
FDM, also referred to as fused filament fabrication (FFF), is a 3D printing method that makes products out of real engineering-grade thermoplastics. 3D design software is used to generate a digital rending of the product. The software subsequently slices the design into a series of laminations or layers. The printer receives the layer data from the computer to reproduce the design by feeding a filament of thermoplastic material through a heated nozzle, which is melted and extruded layer-by-layer on a base platform where it cools and solidifies.
The mechanical properties of the printed part depend on the choice of thermoplastics, structural parameters (e.g., rasters angle, infill density, build orientation, and stacking sequence), and manufacturing variables (flow rate, speed, nozzle, and platform temperature). Because FDM allows for a high degree of customization and precision, it has become a favorite among engineers and designers looking to innovate and iterate designs quickly.
Integrating FDM with Custom Roto Molding
Integrating FDM with custom roto molding can significantly streamline the development of prototypes, especially when complex components with varying wall thicknesses are required. A prototype part can first be printed using FDM to ensure the accuracy of dimensions and fit. Once validated, this part can serve as a pattern for creating the molds used in the roto molding process.
Benefits of FDM for Custom Roto Molding Prototypes
Prototype development for custom roto molding using FDM technology offers numerous benefits, from increased efficiency to the ability to easily create complex designs.
Efficiency – First and foremost, this approach reduces the time and expense associated with traditional manufacturing. Components can be manufactured directly from 3D data in a single-step process, eliminating the multi-stage processes of conventional manufacturing, such as tooling, machining, or creating molds. With this additive technology, which places material only where it is needed, no materials are wasted.
Rapid Turnaround – With FDM, the build time for your complex prototypes is significantly less compared with traditional manufacturing. Designs are completed when you need them, reducing your time to market.
Cost-Effective Design Iterations – Since the process is highly customizable, it allows for rapid iterations without the costs of other prototype methods.
Complex Geometry – FDM allows you to design prototypes with complex shapes with a high degree of precision. Varying wall thicknesses, undercuts, and other tricky design elements are not an issue.
Comparable Strength and Durability – Additionally, since engineering-grade plastics can be used, the strength and durability of materials used meet the demands of functional testing. They can handle real-world applications even in prototype stages. This is particularly valuable for industries where high performance is crucial.
Experience Rapid Prototyping With GVL Poly
At GVL Poly, we use the Fortus 900mc 3-D Production System, which offers the largest print volume of any Stratasys system and the largest selection of polymer materials available. We have the expertise to deliver your high-quality prototypes quickly. We can even apply finishing techniques like painting, electroplating, and wood grain dipping to make it look like the final product piece.
Involving us in the early stages of design ensures the best outcome, but we are willing to help at any stage. From creating concepts, final designs, product documentation, prototypes, and tooling design, we are ready to be your roto molding partner! Contact us to get started.
