Machining, 3D Printing, and Injection Molding: Which is right for your prototype?
In the medical device industry, before a product is
realized, there are generally multiple prototypes made. This can get very expensive. With the technology of 3D printing becoming
more and more available how do you know if that's what you want to use for your prototype? Should you have it machined? What about injection molding? What’s the most cost effective? What will get to you faster? Today I will discuss the pros and cons of all
3 methods.
First of all let’s look at 3D printing. 3D printing is explained as such: “The
creation of a 3D printed object
is achieved using additive processes. In an additive process an object is
created by laying down successive layers of material until the entire object is
created. Each of these layers can be seen as a thinly sliced horizontal
cross-section of the eventual object.”. There are obvious pros
to this. Making only a couple of pieces
is relatively cheap. You don’t have
tooling for machines, you don’t have to pay for the manpower to run a CNC
machine, you don’t have to pay thousands for a mold to be made either. You are also removing human error from the
picture which takes away material loss, time wasted, etc. Last of all, but most definitely not least,
is the time factor. You can get your components made within hours or days rather than weeks or even months. That is definitely a lot of pros. What about the cons of 3D printing though? Once the prototype process is done and you go into production will you then have to have a program created or a mold created? In some cases it would be like starting over. You have to find out what can and can't be machined or molded. What if you need your prototype to be made
from a specific material so that you can test it? What if it has to be stainless or even
copper? Then this won’t work for you.
(Read more on 3D Printing pros and cons)
Next we have Injection Molding. With this method of manufacturing a prototype
there is a high initial cost for the mold to be made, but once that is done
it is quite a bit more cost effective if you need to turn out a lot of pieces.
You get a high production with a low overhead cost. There isn’t much work to be done to churn out
parts after the making of the mold. There isn’t very much human error
involved either.
The component will come out exactly the same, every time. Also, there is a lot less waste with injection
molding. Whatever material isn’t used can be
melted back down for later use. So you
have low production cost, lower material cost, quick production (once the mold
is finished that is), and less handling by human hands. There are disadvantages to this though. The cost for a molding machine is very high
and the machines are huge. We’re talking
anywhere from $10,000-$400,000 and a machine the size of your living room. This can be extremely difficult for a
start-up or even a smaller shop. Also,
if your prototype is very intricate or uses materials not handled by these
machines then you’re out of luck.
(Read more on Injection molding pros and cons)
Finally, let’s discus CNC Machining as a viable option for
your prototype. As with the other 2 options,
there are highs and lows to this method also.
CrossWind Machining uses CNC Swiss Screw Machines to create our components. Probably the best thing about
having machined parts is the ability to make extremely precise pieces. I’m talking thousandths of an inch. A human hair is approximately 3 thousandths
of an inch (.003”). At CrossWind we routinely
make parts within +/- .001” tolerance.
You can’t get those kinds of strict tolerances with 3D printing or
injection molding. Another major pro for
machining is that your prototype can be made out of whatever material your
finished product must be made out of so that you can put it through what testing must be done for approval. Machines are programmable, can hold multiple tools, and have multiple
axis so quite a bit can be done. Now for the cons to machining.
First of all is the wait time.
Machine shops that are slow on work can possibly have your prototype to you in a
couple of weeks. If they are busy
though, it could take a couple of months.
Also, there is the problem of human error. Even when a program is created and perfect components have been machined problems can still arise. Tools on the machine can break or wear out and
have to be replaced. There can be
problems with the material that is being used.
Often the product have to be deburred or a 2nd operation must be
done to them manually or on a separate machine.
They then may need special cleaning or plating done to them. All of these processes require them to pass
through more hands. The more hands on a
part, the more chances there are for mistakes to be made. The parts are put through a thorough inspection process, but sometimes there are mistakes that aren't caught right away.
(Read more on CNC Machining pros and cons)
All in all there are justifications for all 3 methods. They ALL have some very poignant pros and
some frustrating cons. In the end, it
all comes down to what you need to have and what you can do without.
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