Laser Prototypes (Europe) Ltd

Rapid Prototyping

What is Rapid Prototyping? 

Rapid Prototyping is the process of building a solid 3D object, layer by layer, using 3D CAD data. It is popular across a range of industry sectors, and is commonly used in the development of consumer goods, medical devices, aerospace components and other products that require testing/design verification prior to manufacture. 

Key Rapid Prototyping techniques include:

• Stereolithography (SLA)
• Selective Laser Sintering (SLS)
• Vacuum casting
• Concept modelling
• Metal casting

Producing a functional 3D model allows a design to be thoroughly tested before it goes into production. Identifying build issues at an early stage can prevent costly tooling errors later on.

Stereolithography

Stereolithography (SLA) is a time-proven rapid prototyping process used for producing fast, accurate prototype models for verification of product designs. At LPE we have a range of SLA machines offering exceptional levels of accuracy and definition. 

Advantages of SLA:

• Short lead times
• Allows for tight tolerances.
• Accommodates a wide range of materials.
• Produces tough, functional models. 
• Builds in 0.1mm layers. 
• Offers high quality aesthetic models. 

Models produced using SLA techniques can be used for fit and function testing, product photography, wind tunnel testing and many other applications. 

Selective Laser Sintering

Selective Laser Sintering (SLS) is a rapid prototyping process that is often employed when tough, functional models are required for product testing. Models produced using SLS techniques are able to withstand rigorous testing procedures and high temperatures up to 150°C – for this reason they are often used in under bonnet applications, impact testing, or even as final production mouldings. SLS requires very little post-process cleanup, which makes it quicker and cheaper than other processes. Parts can be produced in nylon or glass filled nylon – the complexity of the part is no issue.      
Advantages of SLS:   

• 80% strength of moulded nylon
• Wide Range of MaterialsWide Range of Materials
• Short Lead Times (2-5 Days)
• Tough prototyping materials
• High Temperature Resistance (up to 150°C)
• Builds in 0.1mm layers
• In house finishing & painting

Vacuum Casting

Vacuum Casting is a prototyping process that allows for the faithful replication of plastic parts in a wide variety of near-production casting resins. Customer specified colours (Pantone, BS and RAL) and surface finishes can be accurately matched, as can clarity, colour tinting, impact strength, temperature resistance and flame retardancy. 

Advantages of Vacuum Casting:

• Short lead times (5-8 days).
• Wide range of materials supported.
• Allows low volume production without tooling.
• Colour matching.
• Range of production finishes available. 

Find out more about the Vacuum Casting process by visiting the LPE website. 

Concept Models

Concept models are ideal for communicating design information and are proven to significantly reduce production times and long term costs. They can be produced both quickly and cost-effectively in a range of materials, including foam, modelling board or as SLA and SLS models. They are commonly used for/as:

• Early design verification.
• Ergonomic testing.
• Interactive design reiterations.
• Internal communication tools.
• Early customer buy-in. 

Reaction Injection Moulding

Reaction Injection Moulding (RIM) is a cost-effective method of producing low volume batches of production components. Typical products include automotive trims and bumpers, electronic housings and high temperature components. 

Using silicone, epoxy or aluminium tools, customers can have first-off components within just days of ordering, without the expense and delay of full production tooling. Parts can be fully finished and painted to customer specifications – all processes are carried out in-house by our very own professional finishing team. 

Finishing and Painting

LPE has an in-house team of professional model makers with over a hundred years of combined experienced working with aesthetic and functional 3D models. Drawing upon this experience (as well as state-of-the-art facilities), we’re able to offer a complete in-house finishing and painting service. From aesthetic models to final production units, LPE can deliver a fully finished solution that meets all your design requirements. 

Painting and finishing services carried out by LPE model makers include:

• Inserts and assembly
• Hand finishing
• Spark and gloss painting
• Colour matching
• Water sealing
• Clear/tinted finishing

Rapid Manufacturing

LPE’s rapid prototyping technologies can also be used to meet low volume production requirements – the use of prototyping techniques such as SLS and SLA for small batch production is known in the industry as Rapid Manufacturing, and it is becoming increasingly common as manufacturers look to streamline their production processes. Rapid Manufacturing is a quick and cost-effective way of producing short run components, mainly because it does not require expensive tooling. 

Find out more by visiting LPE online.