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Rapid Prototyping cannot be ignored because they sought to prove the concept of the inventor to potential customers, suppliers, and investors-and most importantly, to the inventor himself. This has been the opinion of majority of experts. The idea behind creating a prototype is the accomplishment of a lot from the point of view of creativity, that too without having to put on so much of money in the idea of product or going for its commitment early on.

Construction of an ‘invention prototype’ at the appropriate time: It’s essential to construct an ‘invention prototype’ much before buying the tooling for building the product or seeking contract manufacturers. Many a times, it so happens that the inventor might, in reality want to build a prototype much before getting too fancy regarding computer drawings. He is likely to burn up loads of cash on ‘engineering drawings’ when possibly what he needs 1st is the papier-mache clearly showing him what is being tried by him. If that is the case, he is advised to revert to computer-aided drawings. Assessing the proper time for prototype is not all that tough. It just requires a proof of workability of the product invented by the concerned person.

The proper ‘invention prototype’ for proper audience: An ‘Prototype’ should be aimed towards the proper audience for doing its job. It means that the tailoring should be done in such a way that the requirements of the customers get fulfilled much to their satisfaction. Not only that, the prototype should be able to bear the critics of potential partners, investors, suppliers, and customers. Hence, it should be noted that just friendly appraisals are not enough. The more slicker looking and operable the prototype, the ‘better’. However, it’s advisable to not get carried away by the praises. It’s better to spend less on this production, as there would be many other places for spending the start up capital.

Let >1 prototype be made

If the overheads are not very much, let the ‘Invention Process’ be made into multiple versions. The inventor is likely to improve the designs subsequently. Due to this, the latest product arrived at would fetch more money owing to its modern and sharp design. Some people also have the habit of making two prototypes at a time. The first one would be meant for ‘show’ and the second one for ‘go’, i.e. the 1st one could be made to look like the end product and the 2nd one for demonstrating the functionality.

For instance- Battery Buddy had a ‘looks-like’ and ‘works-like’ prototype. The 1st one was created at ‘University of Michigan’. A box was fashioned to proper exterior dimensions as per the engineering drawings. It was painted with fancy, fine graphics. This version could fit on around 90% of vehicles in market. The 2nd one consisted of a plastic box. It was grey-colored and around 4 times bigger than actual Battery Buddy. Finishing was not the issue then. The workability had to be checked; and it happened! Hence, the two versions made the task simpler from the buyer’s as well as seller’s point of view.

Several DIY Rapid Prototyping techniques have come up off late. Making a 3D printer at home can prove to be quite cost-effective. The other names for such sort of prototyping are fabbing, three-dimensional printing, reprapping, and fabrication. RepRap is one such 3D printer. Let its making be studied in detail.

RepRap: RepRap is the abbreviation for Replicating Rapid-prototype. In other words, it can be said to be a Practical Self-copying Printer. RepRap would make metal, ceramic, and plastic parts. It’s itself made up of plastic. This is done in order to facilitate the making of multiple copies of its own self. The final product can be described as a 3-axis robot moving numerous material extruders. Fine filaments are produced by these extruders. The filaments are made up of their own working materials. This process has a paste-like consistency.

If one intends making plastic cones, RepRap would make use of the plastic extruder for laying down a 0.5 mm quickly hardening filament made from molten plastic for drawing the filled-in disc. The Plastic Intrusion Head would then be raised and the layer following that would be drawn, exactly on the top of 1st. This process keeps on repeating till the complete cone is formed. If making an Inverted Cone is on the agenda, the same procedure is followed. The only difference would be laying down the support material beneath the parts that are overhanging. The removal of support would take place after the completion of cone. Intermixture of conductors with plastic is allowed. This can help in the formation of circuits.

The process described above is known as RepRap. These machines, though useful, are not very much prevalent. The software of the above process is believed to work on all the computer platforms, that too, free of cost.

Fabr: The Fabr makes use of parts which are commonly available. The other advantages include requirement of minimal fabrication of parts, high accuracy and availability of enough power for not only plastic, but also wood or metal.

The key components of Fabr include 80X20 extruded aluminium, fasteners and bars, drive and anti-backlash nuts, couplers, bearings, aluminium bars, screws, pulleys, timing belts, and ‘A Custom Stepper Motor Controller Board’. The learners are advised to use an Allegro 3967 Micro stepping Stepper Motor Controller. The board contains three drivers, and connectors to have end stops.

DIY 3D printer made from pure sugar: The objectives behind making the above-stated DIY 3D printer are cost-effective design using recycled components, huge printable volume emphasizing over better resolution, and ability of using low-cost print media inclusive of granulated sugar. The process of printing starts with the bed of granular print media which has low melting point. The printing media is fused selectively with a directed, narrow, low-velocity beam. This beam consists of hot air. The bed is then lowered by a diminutive amount. The bed’s top portion is then bombarded with a flat thin layer (of media). By this process, a 2D object is formed. If this process is repeated, 3D object is formed.

Prototyping is a revolutionary and powerful technology with wide range of applications. The process of prototyping involves quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance. The user is able to give immediate feedback regarding the prototype and its performance. Rapid prototyping is essential part of the process of system designing and it is believed to be quite beneficial as far as reduction of project cost and risk are concerned.

Rapid prototyping is known by many terms as per the technologies involved, like SFF or solid freeform fabrication, FF or freeform fabrication, digital fabrication, AFF or automated freeform fabrication, 3D printing, solid imaging, layer-based manufacturing, laser prototyping and additive manufacturing.

History of Rapid Prototyping:

Sixties: The first Prototype techniques became accessible in the later eighties and they were used for production of prototype and model parts. The history of rapid prototyping can be traced to the late sixties, when an engineering professor, Herbert Voelcker, questioned himself about the possibilities of doing interesting things with the computer controlled and automatic machine tools. These machine tools had just started to appear on the factory floors then. Voelcker was trying to find a way in which the automated machine tools could be programmed by using the output of a design program of a computer.

Seventies: Voelcker developed the basic tools of mathematics that clearly describe the three dimensional aspects and resulted in the earliest theories of algorithmic and mathematical theories for solid modeling. These theories form the basis of modern computer programs that are used for designing almost all things mechanical, ranging from the smallest toy car to the tallest skyscraper. Volecker’s theories changed the designing methods in the seventies, but, the old methods for designing were still very much in use. The old method involved either a machinist or machine tool controlled by a computer. The metal hunk was cut away and the needed part remained as per requirements.

Eighties: However, in 1987, Carl Deckard, a researcher form the University of Texas, came up with a good revolutionary idea. He pioneered the layer based manufacturing, wherein he thought of building up the model layer by layer. He printed 3D models by utilizing laser light for fusing metal powder in solid prototypes, single layer at a time. Deckard developed this idea into a technique called “Selective Laser Sintering”. The results of this technique were extremely promising. The history of rapid prototyping is quite new and recent. However, as this technique of rapid prototyping has such wide ranging scope and applications with amazing results, it has grown by leaps and bounds.

Voelcker’s and Deckard’s stunning findings, innovations and researches have given extreme impetus to this significant new industry known as rapid prototyping or free form fabrication. It has revolutionized the designing and manufacturing processes.

Though, there are many references of people pioneering the rapid prototyping technology, the industry gives recognition to Charles Hull for the patent of Apparatus for Production of 3D Objects by Stereolithography. Charles Hull is recognized by the industry as the father of rapid prototyping.

Present-day Prototype: Today, the computer engineer has to simply sketch the ideas on the computer screen with the help of a design program that is computer aided. Computer aided designing allows to make modification as required and you can create a physical prototype that is a precise and proper 3D object.

Hughes was a lifelong aircraft enthusiast, pilot, and self-taught aircraft engineer. He set many world records and designed and built several aircraft himself while heading Hughes Aircraft. The most technologically important aircraft he designed was the Hughes H-1 Racer. On 13 September 1935, Hughes, flying the H-1, set the airspeed record of 352 mph over his test course near Santa Ana, California. The previous record was 314 mph). A year and a half later, (19 January 1937), flying a somewhat re-designed H-1 Racer, Hughes set a new transcontinental airspeed record by flying non-stop from Los Angeles to New York City in 7 hours, 28 minutes and 25 seconds (beating his own previous record of 9 hours, 27 minutes).

On 10 July 1938 Hughes set another record by completing a flight around the world in just 91 hours (3 days, 19 hours), beating the previous record by more than four days. For this flight he did not fly a plane of his own design but a Lockheed Super Electra (a twin-engine plane with a four-man crew) fitted with all of the latest radio and navigational equipment. Hughes wanted the flight to be a triumph of technology, illustrating that safe, long-distance air travel was possible. In 1938, the William P. Hobby Airport in Houston, Texas, known at the time as Houston Municipal Airport, was re-named “Howard Hughes Airport,” but the name was changed back after people objected to naming the airport after a living person.

Hughes received many awards as an aviator, including the Harmon Trophy in 1936 and 1938, the Collier Trophy in 1938, the Octave Chanute Award in 1940, and a special Congressional Gold Medal in 1939 “in recognition of the achievements of Howard Hughes in advancing the science of aviation and thus bringing great credit to his country throughout the world.” According to his obituary in the New York Times, Hughes never bothered to come to Washington to pick up the Congressional Gold Medal. It was eventually mailed to him by President Harry S. Truman.

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