7 Ways the Aerospace Industry Relies on Rapid Prototyping Part 2

Tips for using aerospace prototyping on important projects

The global aerospace industry is already growing by leaps and bounds. However, market experts are forecasting sales increases in the billions by the turn of the millennium. Thrifty manufacturers should jump on the aerospace prototyping bandwagon early to innovate and make great products.

There is a key difference between fabrication, manufacturing, and rapid prototyping. Manufacturing is the process of making a part based on a final design. During manufacturing, the manufactured parts are assembled into a finished product. However, prototyping is the initial phase. Here’s how to make the most of it:

TIP: Think of your prototype as a disposable item

Aerospace prototypes are tools that convey freedom, knowledge, and creativity. They are not marketable products or intended for distribution. Rapid prototyping provides a disposable product for review and redesign, so don’t worry about insignificant features – design parts from start to finish without waiting for an engineer’s input.

Prototyping for aerospace projects should provide critical feedback for design improvements. Teams can create specific models based on goals, alternatives, timelines, and budgets, and fix issues before full testing.

TIP: Focus only on the purposes of the prototype

The scope and size of a project are crucial as they can influence many factors. However, rapid prototyping helps engineers simplify designs and streamline production. The scope and duration of a project can determine costs and lead times.

Experienced designers consider the primary purpose of a prototype before making it. They also consider various screen requirements when evaluating aesthetics, content, and code. Many aerospace prototyping projects lend themselves to sketchy mockups, while others may require full-color compositions. Discuss options with a rapid prototyping expert to create a customized plan.

TIP: Test interactions during development

Rapid prototyping best practices recommend testing designs throughout the development process. Many aerospace engineers use this method to eliminate problems before they become problematic. Teams can quickly improve strategies by creating and re-creating components with variable interactions.

It’s harder to figure out where the design went wrong when teams forget to test during the process. Also, debugging a component to improve it can be expensive and time-consuming. Aerospace prototyping should be efficient and affordable. Therefore, review interactions during development to avoid excess and waste.

DID YOU KNOW: Many marketing companies use rapid prototyping to develop models of trending products for displays and advertising.

Rapid prototyping FAQs

Aerospace engineering relies heavily on high-quality rapid prototyping services. However, the procedures required to do this can be too complex to build yourself. They typically require expert tooling, CNC machining, and intuitive software programming. In ISO-regulated industries like aerospace, automotive, and medical, cutting corners is unacceptable.

Rapid prototyping helps manufacturers pass inspections and lead the way in their industry. Product designers and aerospace engineers should know the most important facts before embarking on a Rapid Prototyping project. Here’s what you need to know:

Is rapid prototyping the same as 3D printing?

3D printing is not the same as rapid prototyping. Rapid Prototyping uses various techniques to create scale models from a CAD file. So additive manufacturing is the manufacturing process, and a prototype is the result. 3D printing sometimes uses rapid prototyping to create custom components, but not always.

What are the pros and cons of aerospace prototyping?

Rapid Prototyping is essential for the aerospace industry, even if it is not a perfect process. Teams can encounter problems or miss deadlines due to various unpredictable factors. The worst thing an engineer can do is expect perfection instead of precision. While rapid prototyping can provide accurate renderings, the results are always dependent on the techniques used.

Aerospace prototyping is also more expensive than model building for other industries. This is because the aerospace industry typically requires high-quality materials and complicated manufacturing processes to meet ISO standards. Rapid Prototyping can help reduce production costs and save time, but only under well-managed conditions.

Even with a great prototype, engineers can overlook critical factors. Teams need to collaborate in real-time to determine the feasibility of designs. As such, many teams keep a flat blueprint for discussion until the last minute.

How much does aerospace prototyping cost?

Aerospace rapid prototyping costs can vary depending on the project, schedule, and materials. However, these are not the only factors at play. Here are other factors that can affect the price:

• product type
• industry regulations
• draft stage
• purpose of the prototype
• size and volume
• surface finish
• post-manufacturing maintenance

Calculate the cost of a prototype considering the different phases. Each phase may have specific pricing depending on the starting point and location.

Concept development – This is the research and decision phase. It is decisive for the result and can help determine the budget. Bring foam models, 3D renderings, and UI mockups to demonstrate your ideas.

Project Engineering – In this phase, teams will quantify and compare concepts to decide on the final design. Engineers can adjust the results while staying on a tight budget by providing feedback before editing.

Prototype and Test – This is where things get interesting as teams get to see their concepts come to life. Functional alpha prototypes help show complexity, improvements, and performance prior to mass production.

Structure of production – Rapid prototyping takes a back seat here in favor of efficient production. This early manufacturing stage helps reduce costs and provides one last chance to change the design before going into production.

Aerospace prototyping doesn’t always require every stage, so discuss options with an expert.

Conclusions

Rapid prototyping is of great importance for the aerospace industry as for many other branches of the economy. It delivers realistic scale models of complex designs for review and approval. However, aerospace prototyping is not flawless, so engineers need to know the pros and cons.

Aerospace engineers can benefit from Rapid Prototyping in several ways such as: through cost reduction, and time management. On the other hand, rapid prototyping can require certain preparation steps that can affect the project goals. Discuss the options and alternatives with a Rapid Prototyping specialist to determine the best plan.