(22) DOB: 2/1/2006

It lives! Finally have my hands on an actual Prototype model, made via a 3-D printer my designer had access to in his SolidWorks classes. It was made using the "SLS" method, or basically a kind of powder laid down, heated, and built up in the shape of the prototype (using the CAD .sla files). The model is kind of fragile, feels like a sandcastle. Very nice feeling to actually touch and feel the model. Good thing it was made, too, before spending $3K on the first run of 8 prototypes (using FDM or SLA); we discovered an opening wasn't quite large enough, a couple of minor tweaks.

Regarding Rapid Prototyping methods, I've got two quotes from 2 different kinds; FDM (basically ABS plastic pellets spit out like a bubblejet printer, building up the model), and SLA (basically layers of liquid urethane successively laid down, heated and fused). The FDM seems like it will be quicker and a bit more durable/possibly flexible (and a little more expensive), the SLA seems like it's harder but more brittle. This is base purely on Internet research and feedback from some Inventor discussions. I've got 4 pieces, 1 large and complex, 2 smaller, and 1 small and easy (i.e. 4 .sla CAD files). The FDM price is about $2200, and the SLA price is about $3100, for 8 prototypes of each of the 4 files. Some discounting for multiple units, but with SLA, this particular manufacturer had 'trays' set up in their machine for lots of 6, so anything over 6 and they need to use a new tray, with less discount. I'll probably try the FDM, first (which prints one at a time).

Now need to concentrate on the other pieces and parts, making sure to order each in sizes that match the final CAD files of the plastic parts. Certainly am spending extra money on little parts that end up not being the right size - lots of trial and error.