What are the most advanced techniques for prototyping complex geometries or materials?

3D Printing is one of the most advanced technologies for prototyping complex geometries using different materials such as polymers and metal. With the newest 3D printers and software applications, it is possible to produce prototypes with sufficient part strength and quality to validate new designs and reduce the time needed for investigation and development .

Cutting-edge prototyping techniques for complex geometries and materials include advanced 3D printing methods like multi-material and multi-nozzle printing, enabling intricate structures and diverse material combinations. Additive manufacturing technologies such as stereolithography, selective laser sintering, and digital light processing offer high precision and versatility. Additionally, advancements in CNC machining and subtractive manufacturing allow for intricate shapes in various materials. These techniques empower designers and engineers to prototype complex and customizable forms, pushing the boundaries of traditional manufacturing processes.

ASTM F42 refers that additive manufacturing or 3D Printing is a process that builds complex geometries layer by layer. The material type can be polymers, resin, ceramic or metal or even their combinations such metal-ceramic combinations.

CNC machining mostly preferred due to its higher tolerance integrity and better surface finish compared to 3D printing. CNC machining operations can be used after additive manufacturing operations to create more accurate and precise features such as holes, assembly interfaces, and threads.

We all know that traditional injection molding is not very well suited to prototyping, or low volume production. But sometimes 3D printing is just not a great option because of surface finish or material properties. More and more we see people 3D printing molds for low-pressure injection molding or for 2-part casting. This allows for use of material not available in 3D printing, and mimics more closely what a production part may be like.

Develop digital twins of complex systems or products to virtually prototype and simulate their behavior under various conditions. This approach enables in-depth testing and optimization before physical prototyping, reducing development time & costs. In an automotive engineering project, we used digital twin prototyping to simulate & refine the complex control algorithms for an autonomous vehicle Explore 3D printing technologies that allow for the simultaneous deposition of multiple materials, including conductive materials, to prototype complex electronic devices & sensors. In an IoT device development project, we used simultaneous multi-material printing to prototype a complex sensor array with embedded electronics.