ProtoCAM Rapid Prototyping Blog

Consumer Products Prototypes by ProtoCAM for Mobigrip

2010-02-26T16:27:00.005-05:00

Mobigrip is a cool new consumer product that helps users of mobile phones and other hand held devices to keep them from falling or being left behind. The Mobigrip sticks to the back or underside of the device and has a micro bungee that loops over the user’s finger to secure the device to the hand. The big benefit is to avoid damaging or losing these expensive devices. Mobigrip can also be customized to be a promotional item.

ProtoCAM worked with Mobigrip to create the stereolithography prototypes that were used in the product development process. ProtoCAM brings a wealth of experience in rapid prototyping for consumer goods, where a fast turn-around in the prototype creation leads to faster time-to-market. ProtoCAM’s plastics engineers have extensive consumer goods prototype manufacturing expertise, and as always with ProtoCAM, design confidentiality is assured.

Check out the Mobigrip or purchase online at http://www.mobigrips.com/. The Mobigrip device leash is made in the USA.

Stereolithography Rapid Prototypes by ProtoCAM for Upgrade Golf Systems

2010-02-17T12:37:00.011-05:00

Andy Kossowsky is always looking for ways to improve the things he uses. An avid golfer and an inventor at heart, Kossowsky was dissatisfied with the typical driving range experience. He felt it was unfortunate there were not many advantageous places where he could put his golf clubs without the fear of having them get damaged or forgotten. That dissatisfaction was the impetus for creating the UpGrade Golf Systems products, where both his golf tray and range divider can conveniently hold up to 8 clubs.

Kossowsky found ProtoCAM by searching on Google for “plastic prototypes” and noted that ProtoCAM was located not too far away from his New York location. Kossowsky contacted ProtoCAM and spoke with Engineer, Ed Graham who guided him to ProtoCAM’s business partner Jim Eldon of Eldon Design Associates. Eldon worked with Kossowsky to move the product development process further along and create the 3D CAD model of the first product, The UpGrade Ball Tray.

ProtoCAM produced the stereolithography prototype in short order and on budget, which Kossowsky used to test and make adjustments in the size of some of the golf club holes. Another prototype was made and this second iteration tested out perfectly.

The second product made was the Range Divider. ProtoCAM again provided the SLA prototype from the 3D CAD model provided by Kossowsky and Eldon. The Range Divider was tested and an improvement in the anchoring system is now complete.

Accura 60 material was the stereolithography material used for all the SLA prototypes.

Kossowsky comments that he “feels spoiled by the experience” because of ProtoCAM’s great service and he “can’t wait to work with ProtoCAM again in the future.”

For manufacturing the products, Kossowsky is now sourcing to make the product using injection molding with polyethylene.

About the UpGrade Golf Products
Both tray and divider provide upright storage and easy access for up to eight golf clubs regardless of grip size. The use of these products eliminates lost clubs that may be left behind or damaged from leaving clubs on the ground or against a fence. The Ball Tray can hold in excess of 90 balls and the Range Divider will allow for an improved area to a person to organize the balls to be used on the range. Both products have a designated area to be used for advertising where the cost of the advertising space can essentially pay for the cost of the tray/divider and in time, will make money for the driving range owner. Both products are patent pending.

About Andy Kossowsky
Andy is a golf enthusiast, author and inventor of both golf products and a unique playing style. Andy invented The PowerSlot Swing, www.powerslotswing.com. Various articles have been published regarding Kossowsky’s swing method, including pieces in publinksgolfer.net and worldgolf.com, and a YouTube video. Along with working on making a feature length video and getting his book published, Andy has also invented a putter and is working on bringing it to market as well.

Check out the Upgrade Golf Products online at www.UpgradeGolf.com.

Snack Palette Launched, Rapid Prototyping done by ProtoCAM

2010-01-27T13:51:00.004-05:00

Snack Palette is a new consumer product that is now available on the market and for sale on the website http://www.snackpalette.com/. It is a disposable/recyclable plate for use at picnics, parties or any other activity so that the holder can hold food and drink in one hand. The Snack Palette is a plate and holder for a cup, fork and napkin all in one and can be used in the left or right hand.

Snack Palette inventor Duane Ebesu started the product development process working with a sculptor to create a clay model of the product. With that model in hand, he contacted ProtoCAM to create the prototype. Ebesu had worked with ProtoCAM on another project and liked their “attention to detail” and “no hassle, never a problem” customer service approach.

ProtoCAM had the clay model scanned to generate the initial 3D CAD representation of the product. ProtoCAM plastics engineer and rapid prototyping analyst Ed Graham worked with Ebesu to understand that the Snack Palette would be manufactured in the future in large quantities using plastic thermoforming. Thermoforming was a better choice for the Snack Palette as it would be less costly to manufacture in the long run than injection molding.

With that in mind, Graham helped provide some design suggestions related to the future manufacturing of the product, so that the thickness of the product would be sufficient to be thermoformed. With these design for manufacturability suggestions in place, ProtoCAM produced the prototype using stereolithography (SLA).

Ebesu comments, “I chose ProtoCAM to do the rapid prototyping because I knew they had a clear understanding of what was needed to get the job done.”

Snack Palette and all its accessories are available online at http://www.snackpalette.com/.

Rapid Prototyping and Product Development for Christmas Light Winding and Storage Device

2009-12-23T08:06:00.005-05:00

STOR’EM is a new product to wind and store Christmas lights, small extension cords, and cables now available from Aloft Enterprises Inc. LLC. Cory Strong is the inventor of the STOR’EM product and President of Aloft Enterprises. Strong worked with ProtoCAM’s engineer Ryan Schmidt in the product development process for the spools that are used to hold stored lights and cords.

The product development process started with Strong’s rough sketch and his initial 3D CAD model of the spool. Strong worked with Schmidt to refine the CAD model with a few improvements and design-for-manufacturability suggestions that were incorporated into the product design.

From that CAD drawing, ProtoCAM produced the stereolithography prototypes that were used in the product development process for product testing and demonstrations.

Cory Strong comments:
"ProtoCAM’s Ryan Schmidt provided invaluable assistance in the product development process to help refine the model. ProtoCAM’s service with engineering and production of the prototypes was outstanding."

ProtoCAM has a long history of assisting customers with perfecting their products in the product development stage, providing significant benefits early in the process when it is easier and less expensive to implement changes.

Check out the STOR’EM cord organizer and light winding / storage device and place an order for these products online at http://www.nolightmess.com/.

The Lehigh Valley’s Morning Call featured STOR’EM in a December 11, 2009 story: Local man invents device to wind and store lights. The product was also featured in a TV spot on Lehigh Valley station WFMZ, including a video on Christmas products that demonstrates the STOR’EM product.

Contact ProtoCAM’s engineers for product development assistance and rapid prototyping work.

Metal Plated Prototypes highlighted in ProtoCAM Tradeshow Video

2009-12-11T13:50:00.011-05:00

ProtoCAM recently exhibited at the Atlantic Design and Manufacturing trade show. At the show ProtoCAM was featured in a
Design World video about ProtoCAM's show offerings.

In the video, Ray Biery talks about some of the example pieces that ProtoCAM brought to the show, including:

An SLA prototype with nickel coating

An SLA prototype with chrome plating for decorative pieces

Tango Black and Tango Gray used for gaskets and seals prototypes

RTV molding used with an SLA piece to create a urethane casting, resulting in reduced lead time and lower costs than injection molding - perfect for about 25 pieces

Quick cast patterns and wax patterns for ferrous or non-ferrous parts

Check out the video and contact ProtoCAM to request a quote for any of these services.

Rapid Prototype Art Objects Donated by ProtoCAM for Kjell Meling Award

2009-11-19T13:56:00.007-05:00

ProtoCAM recently made and donated two award art pieces made using the stereolithography rapid prototyping technology for the recipients of the 2009-10 Penn State Altoona Kjell Meling Award for Distinction in the Arts and Humanities.

The award was designed by artist / Penn State Altoona Associate Professor of Visual Arts Rebecca Strzelec. Strzelec designed the award and ProtoCAM worked with Strzelec to recommend the use of the stereolithography resin material Accura 60, which is used to produce parts with a clear, polycarbonate-like appearance.

As can also be seen in the top view photo, the nested circular cluster shown in the bottom left corner of this photo is the focal point of the award piece. This cluster demonstrates the intricate and beautiful design patterns that can be done using stereolithography for art objects.

In the press release for the award, Penn State-Altoona said:

"The college also extends its gratitude to Rebecca Strzelec, associate professor of visual arts, for designing the award that is being presented to Harvey Pekar tonight and to Ray Biery and Ron Belknap of ProtoCam for providing this coveted
award."

ProtoCAM is no stranger to working with artists to apply rapid prototyping technologies in creating visually stunning 3D art objects. See more examples on ProtoCAM’s Prototype Art page.

If you would like to know more about using ProtoCAM’s rapid prototyping technologies and expertise to create your rapid prototype art objects, please contact ProtoCAM.

Rapid Prototype Plastic Car Engine Components

2009-11-09T13:27:00.005-05:00

ProtoCAM Engineer Ed Graham was recently quoted in a New York Times article discussing the making of rapid prototype auto engine parts. The article, One Step Closer to the No-Iron Car, appeared on October 22, 2009. It talks about the efforts of New Jersey engineer Matti Holtzberg, who has been designing and developing plastic parts for car engines for 30 years. Of course, the percentage of parts in a car that are plastic has been rising for many years, but plastic engine components are currently not common as they have to withstand high temperature and mechanical stress.

As with other car components, plastic engine components are significantly lighter than the aluminum parts they might replace, and material costs are lower. In addition, the manufacturing process can be done at a lower cost.

In the article, Graham notes that ProtoCAM has been using Holtzberg’s technologies for making automotive rapid prototypes used in experimental engines and transmissions for about three years. Graham said, "The thermoset phenolic material is strong and has excellent heat resistance. The process is quick, and the parts go straight into experimental engines and transmissions.”

In this application - rapid prototype engine parts - ProtoCAM is again on the cutting edge of applying rapid prototyping technologies to emerging uses.

If you would like to know more about using ProtoCAM’s rapid prototyping services, product and prototype development services and plastics engineering expertise for your innovative application, please contact ProtoCAM at 610-261-9010 or use the convenient RFQ or Information Request form.

ProtoCAM shows Rapid Prototypes at D2P Tradeshow

2009-10-16T18:07:00.006-04:00

ProtoCAM exhibited at the recent Design2Part trade show, held September 30 and October 1 2009 in Fredricksburg VA. ProtoCAM engineer Ryan Schmidt, who specializes in prototype engineering and plastics engineering, and sales consultant Joe Layman staffed the booth.

ProtoCAM has exhibited at this show and location in previous years. For this show, ProtoCAM brought many examples of SLA prototypes, SLS prototypes, and injection molded parts. Attendance at this show was a little lower than previous years, but there was plenty of traffic at the ProtoCAM booth. A lot of the visitors were very positive about the industry and the economy. It seemed that the hot topic of discussion at the show was new product development - this may be a sign of the rebounding economy. One of the more interesting visitors brought a cut away helicopter propeller to the ProtoCAM booth. He wanted to redesign the prop to fit certain specs. He inquired about making several prototypes so that he could test the contours in a wind tunnel.

ProtoCAM will also be exhibiting at the next Design2Part show: November 18-19 in Greenville, SC in Booth 126.

Would you like to schedule a meeting with ProtoCAM at an upcoming trade show to discuss our rapid prototyping services? If so, please contact ProtoCAM at 610-261-9010 or use our convenient Information Request form - please note in the Comment section that you would like to schedule a meeting.

Media Blasting SLA Prototypes and Parts

2009-10-08T13:12:00.004-04:00

ProtoCAM offers media blasting services to enhance the finish of a stereolithography prototype or SLA part. Media blasting gives the part’s exterior a more consistent look and feel.

ProtoCAM has a special media blasting process with a proprietary media mixture to ensure the part will look appealing to both the eye and to the touch. This process has been refined over many years of media blasting experience to yield superior results.

The two parts pictured here demonstrate the difference in appearance between the unprocessed SLA part on the right and the media blasted part on the left.

Please ask for media blasting when requesting a quote for an SLA prototype / part.

For more information about media blasting for your prototypes or to request a quote for a media-blasted SLA prototype, please contact ProtoCAM at 610-261-9010 or use our convenient RFQ form - please note in the Details section that media blasting is requested.

Color Prototype, Adding Color to an SLA Prototype

2009-09-29T11:42:00.003-04:00

For some uses of SLA prototypes, the color of the prototype is important. ProtoCAM has a well-developed expertise in dyeing stereolithography prototypes using a proprietary process to have the part properly absorb the dye. A prototype may be colored with any of the basic colors such as red, green, blue, purple, yellow, etc.

There are many reasons to color SLA prototypes and parts. Four main reasons for adding color are:

Assembly
Having multiple parts in an assembly may make it difficult to communicate which part is doing what. Coloring the parts provides the advantage of easily indentifying every part and its purpose within the assembly. Dyeing also helps with a precise fit – no extra material is added as with painting. Dyeing will eliminate galling or peeling that may occur from painted parts as well.

Aesthetics
In some cases it is important to color the part to the desired color of the end product. If the end product will be blue, then dyeing could be a fast and simple solution to help bring the SLA to life. While the dyeing process cannot achieve specific colors such as Pantone numbered colors, it can provide the basic colors to provide a part that is close to the production color.

Identification
In multi-piece projects in may be helpful to color all parts of a certain family - blue parts are all part of Project A, red parts are all part of Project B, etc. This will help to quickly identify the parts and keep them with their associated projects. It can also be used to help with keeping track of prototyping revision levels - all green parts are revision 1, red parts are revision 2, etc.

Cost
Dyeing SLA parts is a less expensive alternative to painting. Painting parts requires multiple steps of sanding, priming and painting. Painting can be an expensive process depending on the specific part geometry. The dyeing process is a fast and very cost effective process for most part geometries.

For more information about coloring your prototypes or to request a quote for a color SLA prototype, please contact ProtoCAM at 610-261-9010.

Rapid Prototyping Meets Nanotechnology

2009-09-18T16:21:00.005-04:00

ProtoCAM Managing Partner Ray Biery spoke recently at a seminar hosted by Lehigh University’s Center for Advanced Materials and Nanotechnology. The conference was held at Arkema Inc. in King of Prussia, PA, a producer of industrial chemicals. Biery’s presentation was titled "Low Cost Rapid Prototyping Options".

Biery gave an overview of the rapid prototyping technologies, including stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM), and discussed the different kinds of rapid prototyping materials. He also spoke about the future of the rapid prototyping industry, including the trend to rapid manufacturing and its newest terminologies like additive manufacturing - the creation of production-ready parts.

Lehigh University Visits ProtoCAM

2009-05-27T14:43:00.002-04:00

ProtoCAM recently hosted visiting Lehigh University engineering students. Ray Biery, managing partner, gave the students a tour of the facility and talked at length with the students regarding the multi-faceted business of rapid prototyping. The students posed several question to Mr. Biery pertaining to the industry.

Talking Rapid Prototyping at Design-2-Part Show

2009-05-05T13:01:00.004-04:00

ProtoCAM Plastics Engineering expert Ryan Schmidt reports from April's Design-2-Part Trade Show at the Valley Forge Convention Center:

The Design-2-Part show was a typical Job Shop Show - it was terrific! The number of show attendees exceeded last year, giving us the opportunity to talk about our rapid prototyping services with some new connections and current customers. Talking with existing customers and hearing the positive feedback is the best part for me - it makes all of the customer service work worthwhile.

Rapid Prototyping on Display

2009-04-21T00:47:00.004-04:00

Come visit ProtoCAM at the Design-2-Part Trade Show at the Valley Forge Convention Center. The show is on April 21 and April 22, 2009. Visitor show hours are Tuesday, April 21, 9:00 a.m. - 4:00 p.m. and Wednesday, April 22, 9:00 a.m. - 3:30 p.m.

Ryan Schmidt, ProtoCAM Plastics Engineer will be in attendance along with Dale King, ProtoCAM's Supervisor of Prototypes. Ryan and Dale are extremely versed in rapid prototyping and can answer questions. Visit Ryan and Dale at Booth 209!

Medical Rapid Prototyping: Orthopedic Knee Replacement Prototypes

2009-03-16T21:11:00.005-04:00

ProtoCAM has done extensive work with prototypes for medical applications. A recent medical rapid prototyping project involved an orthopedic prototype for knee replacement. Previous knee replacement orthopedic prototypes had been created using ThermoJet printer, then later using laser sintering (SLS) and CastForm or DuraForm PS material.

In this case, ProtoCAM found a new use for an existing technology. Instead of using SLS, the knee replacement prototype was created by casting it using a stereolithography pattern and founder’s wax. While this is a less sophisticated and older technology, for this application it was a very good fit. The finish on the SLA pattern was very precise and detailed. The benefits to the customer were that the detailed finish was brought forward into the wax prototype that was later used in the investment casting process. Also, the cost of this prototyping process was lower.

Using this rapid prototyping process, the customer was able to identify areas of differential shrink in the final metal casting. That information was then used for the final metal molds that produced the production wax patterns.

ProtoCAM’s innovative use of an established technology helped streamline the rapid prototyping and product development process. For the customer, this cut their time to market by almost 1 year.

ProtoCAM has a very strong practice in many different types of medical rapid prototyping, as this knee replacement prototype demonstrates. ProtoCAM has done work in:

Medical Device Rapid Prototyping
Medical Stereolithography
Rapid Prototype Physical Anatomical Parts
Medical Model Prototypes

ProtoCAM Rapid Prototyping Customer says "Nice Work"

2009-03-02T21:46:00.008-05:00

Right around the time of our last post about Rapid Prototyping: the Importance of Customer Service, Speed, we received the following email from TF Industries, LLC, used here with permission:

We received our 2 complete sets of SLA, SLS proto's in excellent condition and on time. This is the second time we have had ProtoCAM produce our proto's and we are very impressed with the workmanship, expertise, quick service and professionalism that we received, along with our parts, on time!

We look forward in doing business with your company in the future.
This last order was very complex with several types of material for specific parts and Ryan made it a breeze to order. And all the parts were correctly produced to our needs the first time. Nice Work!!!

Best Regards,

Lee Foerster
COO
T F INDUSTRIES, LLC

We appreciate Lee's comments and realize that we have to earn customer trust via good service and timeliness. It's good to know that our customers appreciate that. We were particularly impressed that Lee mentioned "on time" twice!

Ready to try ProtoCAM's speed and service for your next rapid prototype? Just contact us!

Rapid Prototyping: the Importance of Customer Service, Speed

2009-02-17T05:12:00.006-05:00

The November/December 2008 issue of Time Compression magazine had a special feature on service providers in the rapid prototyping/rapid product development arena. There is a survey of users of rapid prototyping service providers, asking 15 questions about service bureaus, technologies, buying processes, etc.

What really jumped out at me was the first question: “When selecting service providers, how important are each of the following when making your decision?"

The top two most important criteria for selecting a service provider were Speed and Customer Service. Price, Material Selection, and Capacity were also deemed important, while Location and an Online Quotation System were not important.

When we at ProtoCAM read this, we now had real customer survey data that supported the primary tenets of our business approach - that speed and service are the most important things we should provide our customers to make us a top rapid prototyping service provider. And of course, these things are related. We have to have good customer service to provide fast prototype development and production. We have to have good systems and processes in place to handle inquiries and respond quickly. We have specifically chosen that phone calls to ProtoCAM are answered personally by real people, not automated answering systems. We have the engineers on staff who can assist with prototype development, CAD drawing and design, and design for manufacturability issues. And our prototyping production capabilities will support the aggressive time constraints that we often encounter and our customers demand, because we know that time-to-market is often a critical factor in the success of a product development project supported by rapid prototyping.

While we have always believed that our priorities were on target to emphasize customer service and speed in our business philosophy and customer interactions, it was good to see that many customers agree!

In the second tier of important decision criteria, we have the prototype manufacturing capacity to meet demand, we are continually exploring new materials to make better prototypes, and we’ll maintain price competitiveness for quotes with existing customers as well as new inquiries.

We look forward to continuing to emphasize service and speed. Contact us to get a rapid prototyping quote and see service and speed in action!

LaserForm A6 Steel and Selective Laser Sintering (SLS)

2009-02-06T12:54:00.009-05:00

ProtoCAM offers the ability to produce parts in A6 tool steel using the selective laser sintering (SLS) process and LaserForm™ A6 steel material. Using LaserForm™ A6 offers our customers an alternative to traditional manufacturing techniques such as sand casting, plaster casting or investment casting. The metal parts produced using SLS and LaserForm™ A6 can be polished, welded, plated and machined. Parts must fit approximately within a 12”x10” envelope with the maximum height being between 6” to 7”. Additionally, all part features must be greater than .040”. The “as sintered” hardness of the part is 10-20 Rockwell “C” but can be heat treated to 39 HRc.

The SLS with LaserForm™ A6 process starts by selective laser sintering a blend of A6 tool steel, tungsten carbide and a binder. When finished, the “green” part is infiltrated with bronze yielding a fully dense part composed of approximately 60% A6 and 40% bronze. Using LaserForm™ material is the definitive solution for low volume rapidly produced metal prototypes, parts or tooling inserts for injection molding. Additionally, if your metal part application is not suitable for using LaserForm™, ProtoCAM offers investment casting, plaster casting and sand casting parts.

Please contact ProtoCAM with your application or any questions you might have about LaserForm™ A6, metal prototypes and metal parts.

LaserForm™ is a registered trademark of 3D Systems, Inc.

ProtoCAM receives MRC Summit Award for Manufacturing Excellence 2008

2009-01-20T08:41:00.006-05:00

The Manufacturers Resource Center (MRC) recently recognized ProtoCAM with the 2008 MRC Summit Award for Manufacturing Excellence. ProtoCAM has worked closely with MRC on many projects and activities over the past few years and is honored to receive this acknowledgment.

The award comes from ProtoCAM’s work with MRC on web marketing efforts combined with active involvement in the area’s economy. It states,

“MRC applauds ProtoCAM for their continuous commitment to investing in their local community through significant quality employment even in difficult times. We commend them for their contributions to the local economy, leadership, and manufacturing in the region.”

As a result of the award from MRC, ProtoCAM also received proclamations from local elected officials, including US Congressman Charles M. Dent, Pennsylvania State Senator Patrick M. Browne, and PA State Representative Julie Harhart.

ProtoCAM is proud of its local presence while serving its customers throughout the world. Many thanks to MRC for this award and to these representatives for the acknowledgments.

How Weather Affects Stereolithography Prototypes

2008-12-30T17:39:00.011-05:00

There are many factors that affect the production and delivery of stereolithography prototypes. Weather is one critical factor. These factors affect the stereolithography process:

Humidity - SLA prototypes can absorb moisture
Heat - SLA prototypes are more brittle when cold and softer when warm

While at ProtoCAM, stereolithography prototypes are made and packed in a controlled environment, so the prototypes do not experience weather extremes here. But they do have to be shipped to customers, so once they leave the ProtoCAM facility, they are exposed to other conditions.

In order properly protect prototypes during shipment, the following precautions are taken:

Prototypes are properly cushioned in the shipping container, which also insulates the part from temperature extremes
Support is provided in the container for the prototype if the shape of the part requires it
The day of the week is considered for shipment - in hot weather, we might delay a Friday shipment until Monday so that the prototype is not exposed to long periods of heat while in transit

With ProtoCAM’s vast prototyping experience, even these seemingly minor details are considered to provide you with the best service and best results.

Request a quote for your next stereolithography prototype!

Subtractive Rapid Prototyping vs. Additive Rapid Prototyping

2008-12-02T14:44:00.005-05:00

ProtoCAM does most of its prototyping work using additive rapid prototyping technologies such as stereolithography (SLA), selective laser sintering (SLS) and 3D printing. Fused deposition modeling (FDM) is another additive rapid prototyping process that is used. With additive rapid prototyping, material is added on or built up in the creation process.

Subtractive prototyping is another way to create prototypes in which material is removed from a larger piece of material. Subtractive prototypes are typically created using more traditional manufacturing processes. These include standard machining process such as milling, turning/lathing or drilling, and more modern tools like CNC machining. So with subtractive prototyping, you might start with a block of metal or plastic and cut away material until the prototype part is created.

In rapid prototyping, there are advantages and disadvantages to any choice of technology. Subtractive prototyping is limited to relatively simple shapes - complex geometries are not possible. The material must be readily available in the size and shape needed. And subtractive RP usually takes longer. Its main advantage is that is made in the final production material.

So if time, design complexities and materials are critical, additive rapid prototyping is likely the best choice. Contact ProtoCAM for additive rapid prototyping services.

Cost of Stereolithography Prototypes: Pricing Factors, How to Reduce Costs

2008-09-10T14:17:00.004-04:00

It seems to be a daily question when customers call ProtoCAM for a quote: “How do you price a stereolithography prototype?” or “What are my options for reducing the cost of my part?”

Stereolithography parts are priced using 5 criteria (in order of importance):

Overall height of the part - Most parts are built using a .004” layer thickness. The exception is a high resolution build which uses .002” layer thickness. The 3D file is “sliced” into layers and then traced and solidified layer by layer on the SLA machine. Consequently, a 6 inch part (1500 layers) will take longer to build than a 3 inch part (750 layers) and therefore, cost more.
Volume of the part - This relates to the number of cubic inches of material that will be needed to make the part. Again, the larger the part the greater the volume of material needed and the greater the cost.
Complexity of the part - When the part is finished on the SLA machine, it will require time to have the excess resin removed as well as having the support material removed. The prototype is then post cured in a UV oven and bead blasted to provide a consistent finish over the entire part.
Finish level of the part - ProtoCAM offers several levels of part finishing ranging from an economy “strip and ship” to a “presentation” level. Our standard level of finish requires the removal of supports with some light sanding on the support surfaces with an overall bead blast prior to shipping. See our Stereolithography Prototypes page to see our offerings of various finish levels.
Lead time of the part - ProtoCAM’s standard lead time is 2 days after receipt of order. Some parts, due to size, require a longer lead time. If you need your prototype part sooner, there is an additional charge to accomplish that requirement.

Understanding the above criteria can make the answer to the second question “What are my options to reduce the cost of my part” seem a lot easier.

Height of Part
Since the biggest contributor to cost is the overall height of the part, the simplest way is to either orient the part with a smaller z height or cut the part in half and allow us to glue it together prior to shipping.

Volume
Reducing the volume to cut the part cost can be accomplished by “hollowing” solid pieces or reducing wall thickness on thick walled parts.

Finishing
If a “presentation” level piece is needed, it can be the customer’s option to perform that work. An experienced customer knows that it can take several hours (or days) to completely sand a stereolithography part, but because of timing or cost the customer may choose to do that work themselves.

Lead Time
The easiest way to reduce part cost is to increase the lead time. If the customer doesn’t need the part within 2 days, increasing the lead time to 1 or 2 weeks will also cut the prototype cost.

Number of Prototypes Ordered
If multiple copies of the prototype may be needed, it is highly recommended to purchase those with the initial run of parts. Economies of scale come into play here and the greater the quantity ordered the smaller the per piece cost.

ProtoCAM will generally orient the part to give the customer the best quality within the shortest amount of time. But if other options need to be explored to meet scheduling or budget constraints, we recommend calling us at 1-800-408-9019. Just ask for the project manager that quoted your project (name can be found in the upper left hand portion of the quote) and we will be glad to explain options that are available to meet your requirements.

Ray Biery
ProtoCAM Managing Partner

Faye talks about the MDM East 2008 Trade Show

2008-06-26T12:22:00.002-04:00

Hi, my name is Faye Stenack and I have been the office manager at ProtoCAM for four years. I remember the first time I walked in the front door at ProtoCAM and found myself totally amazed at the complexity and variety of parts that were produced on the stereolithography machines. I felt like I had just stepped into another world that I never knew existed. Instantly, I knew this was the right job for me and where I wanted to work every day...that has not changed. I am still excited to be a part of the ProtoCAM team. We all have the same objective which is to provide quality parts and service to our customers in a rapid fashion.

I recently had the opportunity to attend the MDM East 2008 Trade Show in New York City at the Jacob Javitz Center. I was astounded by all the different companies that exhibited and the products they displayed. It was quite an eye-opener and a wonderful experience. It was so nice to finally meet some of our existing customers that you usually only get to talk with via e-mail or on the telephone. The positive comments that were shared proved to me that we are doing a good job and listening to the needs of our customers and giving them the quality and service they deserve.

ProtoCAM is a very people-oriented environment and I would encourage you to give us a call or send us an e-mail with your concerns or requests. I feel confident you will become one of our satisfied and valued customers that keeps coming back project after project, too!

ProtoCAM exhibiting at Atlantic Design & Manufacturing, June 3-5 2008

2008-05-27T17:15:00.003-04:00

ProtoCAM will be exhibiting at Atlantic Design & Manufacturing tradeshow next week, June 3-5, 2008 at the Jacob K. Javits Convention Center, 655 W. 34th St. (West 34th Street at 11th Avenue), New York, NY.

ProtoCAM's booth is number 201 - please stop by and visit us there.

Click the coupon below to view important show information and register for a complimentary expo hall admission - a $55 savings.

Using threaded brass inserts to fasten your prototypes together

2008-05-19T10:55:00.017-04:00

When screwing your prototypes together, using the proper technique is critical. Tapping the hole is an option, but the threads can wear relatively quickly in certain prototyping materials. Using self tapping or thread forming screws should be avoided with most prototyping materials, because these fasteners can crack or damage the prototypes. Threaded brass inserts work well when the prototypes must be assembled and disassembled multiple times.

ProtoCAM can assist with the installation of threaded brass inserts into our stereolithography prototypes, as well as SLS nylon prototypes, Polyjet parts, and cast urethanes. There are two types of inserts that can be used in our prototypes, standard and expandable threaded brass inserts. Choosing the correct insert for your application is critical. Please make sure the holes are designed per the tables below.

Standard Inserts

The standard threaded brass inserts work well with all types of prototyping materials, especially SLA prototypes. The inserts are installed into the prototype with an adhesive. Keep in mind that these inserts are only held in by epoxy glue, and should not be used for high torque applications. Recommended minimum wall thickness around the insert is 0.060”. For high torque applications, it would be best to contact ProtoCAM's engineering staff for recommendations. See the chart for the design guidelines when using the standard threaded brass inserts.

Expandable Inserts

The expandable threaded brass inserts works great with durable prototyping materials, such as urethane castings. These inserts are pressed into an undersized hole. As the machine screw penetrates the insert, it expands slightly. This expansion allows the insert to bite into the sidewalls. Recommended minimum wall thickness around the insert is 1/2 the hole diameter, or a minimum of .060”. These inserts provide a slightly higher pull out force, when compared to the standard inserts. For high torque application, it would be best to contact ProtoCAM's engineering staff for recommendations. See the chart below for the design guidelines when using the expandable threaded brass inserts.

Ryan Schmidt
Engineering Manager
rschmidt@protocam.com