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Modelmaking and Rapid Prototyping


     WD offers complete high quality appearance and marketing models.  These models are often used in promotional photography prior to the product being manufactured.  The marketing or appearance model is typically a non functioning color mock-up of the proposed design.  Although it may look real, it is typically made of solid forms and rapid prototyping techniques.     Due to costs of tooling, manufacturing prototyping, a Client may request an appearance model to get final approvals from the management team prior to proceeding to tooling.
  

     Functional and working models are often recommended at the beginning of a project to prove the feasibility of a design.   Functional or working models although they may not look like the final intended design, operate consistent to the base function of the design.   Form models are often used to evaluate form and appearance in relation to the users.  They are typically full or scale models, which are sculpted or machined from solid urethane foams and painted a mono-color.  Mock-up  models are always full scale.  They can be made from a variety of mediums, including cardboard, foam board, wood and sheet metal.  The purpose of a mock-up is to assist in a full scale evaluation of the intended design.  

     Rapid Prototyping and Stereolithography (SLA) Models are our latest development weapon when speed to market is critical.  Modeling a design in ProEngineer® and generating an SLA model can be a fast, effective way to evaluate real world design.  Often a product can be developed and modeled in a matter of days.

     Cast urethane models are the recommended direction when a Client needs more than five or ten units.  This process consists of creating a master model from which rubber urethane molds are cast.  The molds are then used to generate multiple parts of a desired product component.  Urethane models may consist of two to ten different part molds to build a product design.  

     With the introduction of more intelligent products embedded with electronic technology, there is increased need for better user interface design.  Programming a VCR is probably the most famous user interface problem.   Screen graphics, touch panel displays, and compartmentalized menus are some of the areas of focus requiring user interface design.  See Human Factors.

      These are just some of the modelmaking and prototyping techniques we use, and we will be happy to quote any type of modeling you may desire.

Prototype & Modelmaking

RP Fundamentals

Concept Modelmaking

  • Form – Styling Models (scaled - foamboard, renshape etc.)

  • Quick study concept models (cardboard, Styrofoam, etc.)

  • Breadboard – Crude Model

Mock-Ups / Proof of Concept

  • Mock-up Models (full scale models)

  • Engineering Models – mechanical testing / user interface

  • PCB - Breadboards - Board Assemblies

Marketing / Appearance Models

  • Marketing / Appearance Models (photographic quality)

  • RTV - Cast Urethane Models ( 5 - 50 units )

  • Machined – Sheet metal / plastic

RP - Rapid Prototyping (Design / Engineering Verification)

  • Master patterns

  • Electronic PCB prototyping – breadboards

  • FDM - Fused Deposition Modeling

  • LOM - Laminated Object Manufacturing

  • SLS  - Selective laser sintering

  • SLA - Stereolithography – no finishing

Rapid Metal Prototyping

  • EBM  - Electron Beam Metals

  • MLS - Metal Laser Sintering

  • CNC Sheet Metal

Rapid Molding

  • Rapid Injection Mold (Soft Tooling RTV - Urethane or Renshape)

  • Rapid Metal Casting

  • Plaster Casting

  • Investment - Lost Wax Casting  

 

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