For various reasons, the projects we got may not be the CAD file, but the actual physical sample. Sometimes, we even can’t find a drawing for reference, it will be a great obstacles for the use of advanced design methods and manufacturing techniques in the following work.We had to use various measurement way and 3D modeling methods to transform the physical sample into three-dimensional digital model,this process is called reverse engineering.
Reverse engineering work may be more challenging than forward design work, because if you want to make a perfect product, you should understand the design idea of the physical sample firstly and then you may have to repair or overcome the defects of the sample. In a sense, reverse engineering is a process of redesign.
We used the reverse engineering technology for this project.
Customer provided components that were designed and manufactured many years ago and there isn’t any 2D drawing or 3D data that can be used. We recommend that customer provided samples and we will rebuild the 3D drawings by reverse engineering.
3D Printing Prototype
After a thorough analysis of the samples, we finished the 3D drawings for production and start the prototype making.
Because the project had more than 30 parts and some parts were in complex structure, so we chose to use 3D printing rather than CNC machining.
We chose 3D printing with the reason of following main advantages:
Compared to traditional CNC machining, 3D printing is faster. It only took several hours to make a complex structure part, which greatly speeding up this project.
For traditional manufacturing, the more complex product, the higher manufacturing cost. For 3D printing, the manufacturing cost for a complex product does not increase. In other words, manufacturing a complex product does not consume more time, skill or cost than printing a simple square. The project had 5 complex components, so 3D printing is the best choice.
3D printing makes the components with whole shaped technology. The traditional manufacturing way is that the more components a product has, the more time and cost it takes for assembly. 3D printing allows to print the entire assembly at the same time by layered manufacturing and without any assembly.
However, in any case, 3D printing can’t completely replace the traditional machining. For many applications, though, 3D printing can quickly provide prototype validation design with the high precision of functional materials, there are still many limitations in 3D printing, such as material limitations. Although 3D printing can realize printing of plastics, some metals or ceramics, some expensive and scarce materials are still can’t be printing at present. materials that cannot be printed at present are expensive and scarce.
In a word, it requires to combine the traditional CNC machining with 3D printing in projects. If needed, we can recommend the suitable process for customers according to their projects and requirements.
Finally, we finished the 3D printing prototype and sent them to the customer for testing after 4 days.
After the prototype approved, this project moved to the process of injection mold making. The customer required to make the key area stronger and solve the shrinkage problem, our engineer suggested to add ribs on the key area and remove plastic on the thick area to avoid shrinkage problem after analysis. For this case, we got high praise from the customers,”Rex engineers work closely with customer to understand their requirements and make proper solution to achieve the best result with max possibility ”. In a word, this project starts our long-term cooperation with our Australia customer.
Finally, you can find, Rex will provide a project analysis from design, rapid prototype, mold, injection to packing, that will help to save the optimized time and developed cost. Rex is not simply a mold manufacture to deliver the parts according to design, we offer solutions and deliver satisfaction.