Rapid Prototype Service

Deploying a robot in space takes preparation. To help astronauts train to use Robonaut 2 (R2), a humanoid helper, aboard the Space Shuttle Discovery on its final flight, engineers used RedEye On Demand's rapid prototyping service to create a full-scale, high-fidelity mockup.

Created by high-tech firm Wyle, R2 works alongside astronauts, taking over repetitive and dangerous tasks. So the mockup had to duplicate the geometry of the actual R2, with poseable limbs and an ability to withstand rough...

Direct digital manufacturing of plastic parts has come a long way. But, how close are we to do-it-yourself manufacturing?

Advancements in FDM technology are making it possible to not only use additive manufacturing for rapid prototyping, but low-volume manufacturing too. In fact, muscle cars are being restored today using low-volume manufacturing. The Pit Viper, a restored supercharged 1968 Ford Mustang built by TPI (Total Performance Inc.), is an impressive example. After exploring traditional...

By Ruth Jacques

FDM speeds design cycle for cycling app

Real-time analysis of performance metrics can be the split-second difference between first and second place for competitive cyclists. Pedal Brain has created an app for that. Its iPhone accessory logs data to an integrated  Web platform for coach and teammate use.

Highly customized cycles, however, require different brackets to hold the application in place, so Pedal Brain created multiple $300 prototypes via a contracted stereolithography...

The following events, although fictional, are very real problems in companies with low volume product needs.

Design Engineer (DE): " I just spoke with our tooling vendor and they are quoting us $15,000 just for the tool and the lead time is 4 weeks."

Engineering Manager (EM): Gets out his calculator. "We only need 50 parts, that's $300 per part not including their molding costs. We need these out in the field next week if possible. What's with the long lead time?"

DE: "Remember we designed in...

Metal plating of plastics really started to kick in around the sixties when it was discovered that ABS could be pre-treated to ensure proper adhesion of the metal film. The automotive industry was one of the first to really take advantage of the new technique. Automakers could mold trim and other exterior components into appealing shapes and give them a metallic look that inspired car lovers to ogle the beloved vehicle.

With the advent of rapid prototyping and low volume digitally manufactured...