CNC Information

CNC Software and GCode Videos on CNC Machining

Learn DIY CNC Machining – Hobby CNC Plasma Cutter

Here is a summary of video’s 5-8:   Video 5: In this video Ivan goes through Mach 3 to look over the g-code. He checks to see if we have any problems before we go to the CNC Plasma Cutter.   Video 6: Ivan heads out to the shop and do some work. He shows how he zeros out the cnc plasma cutter and starts cutting the aluminum stomp pad. Once he is done, the stomp pad gets looked over and he notes the slag or dross we will have to grind off next.   Video 7: In this video Ivan rough grinds the cnc stomp pad to remove the dross. It’s a rough grind because later we will use a DA Sander to smooth it all out.

Video 8: During this CNC Video Segment Ivan sands our CNC Stomp Pad with a Dual Action (DA) sander. The CNC Plasma Cut part then is taken over to a stand. Then Ivan starts to look at different traction spikes and how they will look.   Video 9: In this video the holes are drilled in the CNC Stomp Pad. The holes are drilled and then Ivan cleansthem out. We bend the stomp pad while drilling and we must hammer it flat next.   Video 10:Here is the final video in the CNC Stomp Pad Tutorial Video Series. In this video, Ivan goes over the final assembly of the stomp pad. Then we watch as we used double sided tape to adhere it to the snowboard. Finally we take a look at some final photos of the CNC Stomp Pad on the Snowboard.   Ivan has created a unique and personalized video tutorial series that that leaves the viewer anticipating the next video in the series. The complete video series from start to finish can be viewed at:CNC Router . You can always check on Ivan’s website to find his latest CNC projects and Hobby CNC Information.   About CNC Information: CNC Information is an information website that offers users a deeper insight into CNC.

CNC Plasma and New CNC Machine Project

Ivan Irons at CNC Plasma has just completed the design phase of a new video tutorial series on a CNC Stomp Pad Project that is shot in sequential steps.  It is a step-by-step personal account of a CNC project from the design phase to the end product. It contains useful design and machining tips for all CNC enthusiasts.

The video tutorial series was made to take beginner to intermediate CNC hobbyists through the major steps in the CNC process. Ivan narrates each video with technical, yet easy to understand descriptions of the process along with useful personal tips from his CNC experience. Ivan’s video series starts out with the design phase, which includes all of the computer design, CAD, and CAM work.

This first release contains 4 design videos:   Video 1: An overview of the CNC Project that is shot in a tutorial sequence. Ivan walks you through the entire process by discussing the Design, CAD, CAM, Control, CNC Plasma Cutting and then final assembly phase. CNC Machine   Video 2: Ivan starts the design of the CNC Stomp Pad. He uses Adobe Illustrator to sketch it out and prepare something that a CNC Plasma Cutter could follow. CNC Router   Video 3: This video starts with the design in CAD. It gets resized to specific dimensions and then is converted it into a DXF File.

Video 4: In this last design video, Ivan sets the CAM Programming parameters in SheetCam. Next the G-Code for the project gets finalized and you also get a quick look at some CNC Post-Processing.     Ivan has created a unique and personalized video tutorial series that that leaves the viewer anticipating the next video in the series. The second set of video’s showing the machining and final assembly is set to be released at the end of this month. The video’s can be viewed at: You can always check on Ivan’s website at  to find his latest CNC projects and video’s.   About CNC Information: CNC Information is an information website that offers users a deeper insight into CNC.

CAM Process Defined – DIY Computer Aided Manufacturing Tutorial

Ivan Irons at CNC has just completed a new CNC Basic E-Course learning series about the CNC Process. Ivan has just completed video four which is all you need to know about Computer Aided Manufacturing in the series of 6 video’s; video’s 1 thru 4 were previously released. It is a seven part video course that walks an amateur through the basic process of CNC. Those who are beginning to learn CNC will benefit greatly from Ivan’s easy to understand CAM instruction.

The CNC basics E-Course is a video series that was created for the CNC Beginner to give a brief overview of the major steps of the CNC process.  Ivan made sure to use simple language to explain complex processes and narrates each video with his own personal tips included.  The six videos in the basic E-Course will cover the five prominent steps in CNC:

Design

Cad

Cam

Controlling

Machining

The videos in this basics series that have been released can be found at: CNC Videos

Video4:

Ivan focuses video 4 on CAM. CAM stands for Computer Aided Manufacturing. During the CAM step of the CNC Process Ivan uses software to teach how our CNC Machine should move. There are a number of CAM Software packages on the market which Ivan walks the user through in this video. Ivan goes through CAM Software techniques where he defines things like stock, location, tooling, feed and speeds and the post processor in use.

Ivan seems to have a talent for taking a complex topic such as CNC, picking out the most important aspects, and breaking down those topics into laymen terms. Ivan has started a fantastic CNC basic E-course. Video’s 5 and 6 in the series are set to release in January of 2008.

You can find the CNC Basic E-Course Video’s at Ivan’s Blog: CNC Blog.  You can always check on Ivan’s website at CNC Videos to find his latest CNC projects and video’s.

About CNC Information:
CNC Information is an information website that offers users a deeper insight into CNC. 

How to Build a CNC Machine News CNC Website

How to Build a CNC Machine, a secret that all DIY CNCers want to know, can now be found at DIY CNC.  There’s information for a beginner walking off the street who decides he wants to know How to Build a CNC Machine.

CNC Future has detailed transcripts of the step-by-step process of how to build a cnc machine from the first steps of deciding why you would want a cnc machine to final assembly. These transcripts lay out every step and detail from an expert CNC hobbyist who has built many CNC Machines in his lifetime.

These transcripts are available for free along with a series of videos that mimic the transcripts. These videos allow you to read the transcripts then watch the steps being taken. These videos allow the user to pause, stop, rewind the video’s and watch them as many times as needed for refrence when taking on this project to Build A CNC Machine. Go to CNC News to see the videos.

The most amazing part about this is that these transcripts and videos are free for all of the DIY CNCer’s out there who want to learn How to Build a CNC Machine. This step by step video and transcript process was done by an avid CNCer who wanted to share his experience and knowledge with CNC Beginners who don’t have to spend thousands of dollars purchasing a ready made CNC table. Visit CNC Machine to see the latest CNC News and Information.

About CNC Future: CNC Future is the premiere news website for the latest information on the Future of CNC.

CNC News Website Released for the CNC Digital Machinist

Cast Prototyping and Precise Cast Prototyping

The Cast Prototyping and Precise Cast Prototyping is a new webpage that was just added to the new Rapid Prototyping Information Website that has just been released. This new PCPro Technique Process webpage has all of the information you need to know on Cast Prototyping and PCPro Technique and the main information you need to know on Cast Prototyping. You can visit this Cast Prototyping webpage at: Cast Prototyping

 Here is an excerpt from the new Cast Prototyping and PCPro Technique webpage: 

“Researchers have developed a new rapid-prototyping technique that blends traditional casting methods with CNC milling which allows faster prototyping; the best thing is that it happens in a single machine. The technique is christened as “Precise Cast Prototyping” or PCPro and was developed by researchers at the Fraunhofer Institute For Material and Beam Technology, Dresden, Germany. Half of the mold is machine using CNC machining, then silicon or polyurethane material is poured into fill half the mold, this will be the lower half to render the shape of one half of the part, while the part still in the CNC mill. When the material is cured and hardened, the upper side of the component is milled. The process is targeted at components with simple geometry such as housings whose one side can be fairly easily machined on aluminum or epoxy mold half and the other complicated half is on the opposite side where it can be milled into the soft plastic. “

The new Cast Prototypes page is free information to members and non-members and can be found at:  Prototyping . However, users of Prototype Zone who decide to be members can join for free and receive two free E-Books on Rapid Prototyping for a limited time offer. Prototype Zone will be adding new information all the time on Rapid Prototyping so check back often in the forum and blog for the latest information at: Cast Prototyping

 About Prototype Zone: Prototype Zone is the leading information source and community website for all things about Prototyping and Rapid Prototyping. Visit the website to join for free and receive two free ebooks on Rapid Prototyping for a limited time offer.

Prototype Design and Prototype Development

The Prototype Design Process is a new webpage that was just added to the new Prototyping Website that has just been released. This new Prototype Design webpage has all of the information you need to know of Prototyping and Design Prototyping and the main information you need to know on Designing Prototyping Inventions. You can visit this Designing Prototyping Process webpage at: 3D Prototype

 Here is an excerpt from the new Prototyping and Designing webpage: 

“Designing: Designing is the process by which you will design a product in advance before actual production. Designing will help you to innovate, change, modify and invent. Designing involves the process of idea generation, conceptualizing and actual design development.

Prototyping: Prototyping is a process in which a working model or prototype is developed for the purpose of testing the various design aspects like features, ideas, viability, functionality, output and performance. The prototyping will help in getting a quick user feedback. Prototyping is considered to be an essential element of the process of system designing.

Designing and prototyping go hand in hand, as both are complementary. In prototyping, new prototypes are developed on the basis of the performance of earlier designs. The deficiencies or problems in the previous designs can be detected and corrected. The prototype is redesigned after refinement and successfully meets the designing goals like functionality, manufacturability, performance and robustness. After this, the product can be readily produced.”

The new Design Prototype page is free information to members and non-members and can be found at: Prototyping. However, users of Prototype Zone who decide to be members can join for free and receive two free E-Books on Rapid Prototyping for a limited time offer. Prototype Zone will be adding new information all the time on Rapid Prototyping so check back often in the forum and blog for the latest information at: Designing Prototypes

 About Prototype Zone: Prototype Zone is the leading information source and community website for all things about Prototyping and Rapid Prototyping. Visit the website to join for free and receive two free ebooks on Rapid Prototyping for a limited time offer.

How PCB Prototyping Works

PCB Prototyping Process is a new webpage that was just added to the new Prototyping Website that has just been released. This new webpage has all of the information you need to know of PCB Prototyping and the main information you need to know on Prototyping Technologies. You can visit this PCB Prototyping Process webpage at: PCB Prototyping

 Here is an excerpt from the new PCB Prototyping webpage: 

“Origin: Rapid prototyping has taken virtual designs through ‘animation modeling software’ or ‘computer aided design (CAD)’. Thereafter, transformation into virtual, thin, horizontal cross-sections takes place. Each cross-section then gets created in the physical space. This process goes on till the model gets completed. It is better known as WYSIWYG process. Let's understand this process in detail.

WYSIWYG: WYSIWYG as the abbreviation for ‘What You See Is What You Get’. It is used in ‘computing’ for describing a system wherein content looks similar to final product at the time of editing. It is generally used in word processors. However, this use is in the form of HTML (Web) authoring. The popularization of this phrase was carried out by the comedian ‘Flip Wilson’. His character ‘Geraldine’ used to say this very often to give an excuse against her idiosyncratic behavior.

This expression came to be applied later to computer-based applications as practicality in technology arrived. At times, it is phonetically spelt as ‘Wizzywig’ or ‘Wizywig’. It has also been used as a brand name for a ‘lighting design tool’ utilized in theatre industry to pre-visualize the shows and 3D CAD.

The process further : The additional fabrication causes the machine to read data from CAD drawing. After that, consecutive layers of powder, sheet material, or liquid are laid down. Likewise, a model gets built-up from a chain of cross-sections. Such layers, corresponding to CAD model’s virtual cross section, are then fused automatically or joined together for creating the ultimate shape. The basic advantage of additive fabrication goes to state that any geometric feature or shape can be created through this.”

The new PCB Prototyping page is free information to members and non-members and can be found at: Rapid Prototyping. However, users of Prototype Zone who decide to be members can join for free and receive two free E-Books on Rapid Prototyping for a limited time offer. Prototype Zone will be adding new information all the time on Rapid Prototyping so check back often in the forum and blog for the latest information at: Prototype Forum

About Prototype Zone: Prototype Zone is the leading information source and community website for all things about Prototyping and Rapid Prototyping. Visit the website to join for free and receive two free ebooks on Rapid Prototyping for a limited time offer.

Art Casting Information

Metal Art Casting Information and stats on the various types of Artistic Casting can now be found at a new section on Metal Casting website that is all about Metal Art Casting. The new Metal Art Casting section can be accessed by users and non-users by visiting the following web address: Art Casting

Here is an excerpt from the Art Casting section page on Metal Casting Zone:

“Art casting is one form of excellence, put with diverse craft skills. It should be perfect and graceful at the same time. One should have unique craft skills which can produce a perfect art casting. There are several websites which can provide a person with information on art casting technique, their sculptors and the craft skills which are required to be a sculptor.

The websites that showcases the Art founders combines to provide advanced foundry techniques and similar superb craft skills. One can thus understand the sculptor’s needs and vision after viewing the art form. Previously, such sculptors were used in museums, galleries and exhibitions. Even today, at large the sculptors are used in public places, galleries and such art casting are made out of modern equipments and casting techniques.”

The new Art Casting webpage is there to provide users with all of the information they need on Artistic Metal Casting and learning the basics of Metal Art Casting. It can be visited for free at: Art Casting This new section of Metal Casting information will continue to be updated with the latest and greatest information on the basics of Art Casting at: Casting

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Cupola Casting Information along with Cupola Foundry Information Just Released

Cupola Casting Information and stats on the various types of Cupola Furnaces and Cupola Foundry’s can now be found at a new section on Metal Casting website that is all about Cupola Casting. The new Cupola Casting section can be accessed by users and non-users by visiting the following web address: Cupola Furnace

Here is an excerpt from the Cupola Casting section page on Metal Casting Zone:

“A Cupola is a type of furnace that is very much alike to blast furnace. The Cupola furnace is refractory lined, stack of steel that is around 20 to 35 feet high. It rests on a base plate that is made of cast iron and has four legs. The casting that is obtained from the cupola furnace is known as a cupola casting.

Cupola Furnace: The Cupola furnace is one of the oldest forms of furnace that have been used by the iron and metal foundries. The Cupola furnace is the crudest and the simplest furnace that has been used by the industries. However, the cupola’s use is declining and the furnace is fast being extinct.”

The new Cupola Casting webpage is there to provide users with all of the information they need on Cupola Casting and learning the basics of Cupola Foundry’s. It can be visited for free at: Cupola Casting. This new section of Cupola Casting information will continue to be updated with the latest and greatest information on the basics of Cupolas at:  Casting Furnace

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Backyard Foundry and DIY Home Foundry Information Just Released

Backyard Foundry Information and stats on the various types of Home Metal Casting Foundry’s can now be found at a new section on Metal Casting website that is all about DIY Metal Casting. The new Backyard Foundry section can be accessed by users and non-users by visiting the following web address: Backyard Foundry

Here is an excerpt from the Backyard Foundry section page on Metal Casting Zone:

“People who like to make their own artifacts and are enchanted with the idea of building new and useful things from scratch are sure to enjoy ‘do it yourself casting’ that can be done at home using simple methods and techniques. Many amazing things can be produced and created using you home made metal foundry. A good understanding of some basic foundry knowledge and few simple tools can help you make metal casting at home possible. Many people find it difficult to get special parts for their cars or bikes or even find it very costly to modify their cars, house or even bikes. If you develop your hobby of metal casting, then you can easily make special parts for your cars and bikes and also will find it easy and save a lot of money. Casting can be used to make many things like, simple ornaments knobs and even handles.”

The new Backyard Foundry webpage is there to provide users with all of the information they need on DIY Metal Casting and learning the basics of Metal Casting. It can be visited for free at: Home FoundryThis new section of Home Foundry information will continue to be updated with the latest and greatest information on the basics of DIY Metal Casting at: Backyard Foundry

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Welders Community, Welders Club, Welders Tutorials

Welding is a popular job and a popular hobby for many people throughout united states and many other countires. There are a series of new websites on welding that will be ready for viewing soon. Welders are looking for a variety of resourses on welding that aren't currently on the internet. These new websites will provide welders everywhere a place to find welding information, meet with other welders throughout the world, and learn the latest information on welding and welders. These new websites are set to be in beta testing mode and will be launched in the near future. Welders everywhere can expect to get welding knowledge on the new welding knowledge website that is for new welders learning about welding and wanting to get new information on welding. There will also be a welding club website that will be a new website that provides a place where welders can form a community and club of welders to talk about welding, share stories on welding, and learn from different welders all over the world. Another website will round out the three new welding websites that will be all about welding tutorials. This website will provide tutorial welding videos to help welders everywhere not just read to learn about welding but actually be able to see techniques for simple to complex welding tasks. These welding tutorials will be available for vieweing for welders everywhere. These website on welding are sure to set the world of welders on fire with new welding information, welding videos and welding communities.

Welders World New Welding Website

Just released is a new welding website. This new welding website is just getting started and is currently in beta testing mode. The welding website is going to go through some major changes in the next few months. The website is set to be the premiere website for all of the welders in any part of the world. The website is set to be the new community for welders of tig or mig welding. 

This new welding website, called Welders World, will feature Welding Articles with various tips on wedling, new welding advice, and some old welding tricks. The welders community will also feature a blog. This welders blog will have the newest information possible on welding and will be constantly updating to provide all community members with one single place to go to get all of their welding information.

Also, the wedling world website will have a welders forum with community members can have their own profiles to feature thier welding projects and skills. The forum on welders world is also a great place to talk welding with welders all over the world. Here, questions and answers can be discussed with the best welders in the world.

 The new Welders World website can be set to launch in just a few short months. Check back often to the Welders World website to see the changes and new content added to the premiere welding community on the world wide web.

Metal Casting Information and Basic Metal Casting Information Released

Metal Casting Zone has just released a new section of their website that has all of the basics on Casting, Metal Casting, and Die Casting. This is part of a new community website that is all about Casting. Members and non-members can visit this Casting page on the Metal Casting website for free at: Metal Casting

Here is an excerpt from the new Metal Casting information webpage:

 “Casting can be defined as a process of manufacturing, which implies pouring of a ‘liquid’ material into ‘A Mold’ containing a desired shaped hollow cavity, and then made to solidify. The ejection or breaking out of the casting then takes place to get the process completed. The use of casting is ‘forming hot liquid metals’ or numerous metals that are cooled after having the components like clay, plaster, concrete, and epoxies mixed. Complex shapes are normally made by casting, as other methods are not feasible. Casting came into being around 6000 years ago. ‘Copper Frog’ is the most ancient casting existing till date since 3200 BC. The process of casting has two distinct subdivisions: non-expendable and expendable mold casting. ‘Non-expendable’ mold casting: This technique is inclusive of at least 4 distinct methods: continuous, centrifugal, die, and permanent casting.  Continuous casting: Continuous casting can be defined as a refined process of casting for high-volume, continuous production of ‘metal sections’ with constant cross-section. The pouring of molten metal into a water-cooled, open-ended copper mold takes place. This allows a ‘layer’ of ‘solid metal’ to be formed above the ‘still-liquid’ center. Continuous casting is widely accepted due to its cost-effectiveness. The metals continuously cast are aluminum, copper, and steel.” There is plenty of more information on the new general information metal casting website that can be found by visiting: Casting. There is also a special going on now that allows members to gain access to free ebooks and other free materials just for signing up as a member of the casting website for free at: Die Casting. Users should check back often to the metal casting general page as more information will be added as the website expands and grows. About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Electric Arc Furnace, Blast Furnace, and other Metal Casting Furnaces Just Released

Learn Metal Casting Processes and Metal Casting Techniques Just Released

Learn Casting and all about Metal Casting, and Casting at a new section on Metal Casting website that is all about Learn Casting. The new Learn Casting section can be accessed by users and non-users by visiting the following web address: Metal Casting

Here is an excerpt from the Learn Casting section page on Metal Casting Zone:

“There are various casting processes being implemented now days. The oldest amongst them is sand casting. Spin casting is also widely used. They can be described as follows:

Sand Casting: Sand casting involves formation of mold from a mixture of sand and to pour a casting liquid, most probably, a molten metal into mold. The metal is then allowed to solidify and the removal of mold, takes place. Sand molding consists of two types: green sand method and air set method. The first one consists of mixture of clay, moisture, silica, and many other additives. The second one consists of mixture of dry sand and other materials, not moist clay. They are mixed with the help of a quick curing adhesive. The collective use of these materials is called ‘air set’.

At times, there is temporary plug placed to pour the fluid which is to be molded. Air-set molds usually form molds consisting of two parts-the bottom and the top. The mixture of sand gets tamped down after its addition. It does not generate any by-product. After the solidification and cooling of metal, the mold gets usually destroyed. This is because its removal involves a lot of breaking and cracking. The casting accuracy depends a great deal on the sand and the process of molding used. Castings composed of green sand result into formation of rough texture on casting surface, and this characteristic makes them easily recognizable. Air-set molds produce smoother castings.”

The new Learn Casting webpage is there to provide users with all of the information they need on casting and learning the basics of metal casting. It can be visited for free at: Learn Casting .This new section of learn casting information will continue to be updated with the latest and greatest information on the basics of casting at: Learn Casting

About Metal Casting Zone: Metal Casting Zone is a Community Site that brings users into a deeper relationship with Metal Casting.

Virtual Prototype, Virtual Prototypes, and all Virtual Prototyping

Virtual Prototyping is basically as simulation based refinement of a component by using a function based simulation. The technology is rapidly gaining prominence as the practice of choice amongst engineers, thanks to its ability to immensely shorten cycles and aid faster product development. Other major reasons for rapid proliferation of the technology include the widespread availability of low-cost computers and analysis tools and the ability to integrate multi-physics simulations into a single environment. These days, computer simulations are increasingly used to calculate and evaluate the kinetic and geometric reactions of a system to various external factors.

The fact that the results can be visualized in full 3D environment has further spurred the rise of this technology. This has finally set the stage for a brand new phase in product development; the engineer can now quantitatively assess the performance of a system by saving the expenses on the intermediate physical prototypes. Virtual Prototypes also permit a larger variety of tests to be carried out on the models, sans any risk of over-testing such as wearing out the component. This is a major boost to the process of redesign as the desired results could now be achieved a lot faster. Virtual Prototypes also facilitate the involvement of non-engineering staff such as sales personnel and management very early in the development process. In this way virtual Prototyping has gained acceptance as the weapon of choice for mechanical design system and is now widely used in sectors ranging from automotive, rail, aerospace to medical device designs. There is significant shortage of individuals trained in the methodology which seems to be the biggest crisis the mechanical design industry is facing.

Virtual Prototyping is the process of representing a 3D representation of your invention by the use of CAD softwares. Most prototyping companies allows their client to see the result online, in the comfort of your home you can get a 360 degree view of your component or flip it one end over another. Virtual prototyping is probably the most convenient means of communication between a designer and his customers. No matter where you are, you can do business with anyone in just about any part of the globe.

Cast Prototyping and Precise Cast Prototyping

Researchers have developed a new rapid-prototyping technique that blends traditional casting methods with CNC milling which allows faster prototyping; the best thing is that it happens in a single machine. The technique is christened as “Precise Cast Prototyping” or PCPro and was developed by researchers at the Fraunhofer Institute For Material and Beam Technology, Dresden, Germany. Half of the mold is machine using CNC machining, then silicon or polyurethane material is poured into fill half the mold, this will be the lower half to render the shape of one half of the part, while the part still in the CNC mill. When the material is cured and hardened, the upper side of the component is milled. The process is targeted at components with simple geometry such as housings whose one side can be fairly easily machined on aluminum or epoxy mold half and the other complicated half is on the opposite side where it can be milled into the soft plastic.

Cost Saving: The technique is touted to be an enormously cost effective as only one half of the tool is made and that too for low pressure casting. There are no runners; gate, venting and parting lines to be taken care of and besides these can be manufactured by toolmakers with lesser experience. Another advantage is that one half casting allows the air bubbles to escape freely; this translates into a more dense part and better surface finish. Since the casting is machined again it allows features such as threads and undercuts to be incorporated. The casting method shapes the outer surface of the component while precision CNC milling renders the inner contours. The fact that he casting can be milled allows for parts with totally different dimension to be manufactured from the same mold. This is because the second half of the mold exists only as a CAD/CAM model and tool path programming. Geometrical changes can be altered by just changing the parameters.

Time saving: Since the outer surface of the component are not machined the process saves a lot of time .Moreover the inner dimensions gain closer tolerances compared to prototypes manufactured by vacuum casting. The reason for this is that the finishing takes palce after the curing and shrinkage in conventional prototyping while in casting it’s done before the casting shrinks. CNC allows for achieving of tighter tolerances compared to casting technologies. Besides all the machining is done in a single setting so there is no chance of non-alignment of the outer and inner features. The PCPro technique manufactures a prototype in just 6 steps, while the vacuum method takes 15 steps.

Injection Molding

Approximately 30% of all plastic products in the world are produced by an injection molding process. Within this another 30% are produced using a custom injection molding technology. There are basically six steps involved in the normal injection molding process. The first step is the clamping of the mould, the clamping unit makes for one of the three units of the molding machine. The other two being the injection unit and the mold, once the clamping unit holds on to the mold, the molten plastic is injected into the mold by the injection unit. The plastic is fed in the form of tiny pellets onto a hopper. These are then allowed into a cylinder where they are heated into a molten state and injected into the mold. The steps that follow are referred to as dwelling phase. It basically involves making sure all the cavities in the mold are fully filled. The mold is then allowed to cool with the clamping intact. Finally the mold is opened and the component is ejected out. The biggest advantage of plastic injection molding is the cost factor of the produced parts, especially when you need large number of parts. The disadvantage is the cost of manufacturing the molds; a simple injection mold can cost you $3000 while the bigger complex ones can run into several hundreds of thousands.

Rapid Prototyping: Rapid Prototyping is the process of automated manufacturing of physical components using solid freeform fabrication. They are used in a wide range of applications, everything from medical to fine art. Rapid Prototyping machine works by taking virtual models from software and then converting it into extremely thin, horizontal cross-sections and then goes onto create each of the cross-section in physical space in a cyclic manner until the model is completed. Rapid Prototyping is a WYSIWYG process in which the virtual model bears identical resemblance to the finished physical model. Additional fabrications allows the machine to lay down layers of sheet, liquid or powder material and build up a series of cross-sections These layers are finally automatically fused together to render the final product.