Rapid Prototyping

Looking for more than a desktop 3D printer can provide? Need an alternative to your in-house capabilities? Our industrial 3D printing service ensures accuracy and repeatability so you get highly precise parts—every time. At Higear Group, additive manufacturing is designed for functional prototypes, complex designs, and production components in as fast as 1 day.

Which 3D Printing Process Should I Use?

Stereolithography

Stereolithography (SLA) is an industrial 3D printing process used to create concept models, cosmetic prototypes, and complex parts with intricate geometries in as fast as 1 day. A wide selection of materials, extremely high feature resolutions, and quality surface finishes are possible with SLA.

How Does Stereolithography Work?

The SLA machine begins drawing the layers of the support structures, followed by the part itself, with an ultraviolet laser aimed onto the surface of a liquid thermoset resin. After a layer is imaged on the resin surface, the build platform shifts down and a recoating bar moves across the platform to apply the next layer of resin. The process is repeated layer by layer until the build is complete.

Newly built parts are taken out of machine and into a lab where solvents are used to remove any additional resins. When the parts are completely clean, the support structures are manually removed. From there, parts undergo a UV-curing cycle to fully solidify the outer surface of the part. The final step in the SLA process is the application of any custom or customer-specified finishing. Parts built in SLA should be used with minimal UV and humidity exposure so they don’t degrade.

Selective Laser Sintering

Selective laser sintering (SLS) is an industrial 3D printing process that produces accurate prototypes and functional production parts in as fast as 1 day. Multiple nylon-based materials are available, which create highly durable final parts.

How Does Selective Laser Sintering Work?

The SLS machine begins sintering each layer of part geometry into a heated bed of nylon-based powder. After each layer is fused, a roller moves across the bed to distribute the next layer of powder. The process is repeated layer by layer until the build is complete. When the build finishes, the entire powder bed with the encapsulated parts is moved into a breakout station, where it is raised up, and parts are broken out of the bed. An initial brushing is manually administered to remove a majority of loose powder. Parts are then bead blasted to remove any of the remaining residual powder before ultimately reaching the finishing department.

Direct Metal Laser Sintering

Direct metal laser sintering (DMLS) is an industrial metal 3D printing process that builds fully functional metal prototypes and production parts in 7 days or less. A range of metals produce final parts that can be used for end-use applications.

How Does Metal 3D Printing Work?

The DMLS machine begins sintering each layer—first the support structures to the base plate, then the part itself—with a laser aimed onto a bed of metallic powder. After a cross-section layer of powder is micro-welded, the build platform shifts down and a recoater blade moves across the platform to deposit the next layer of powder into an inert build chamber. The process is repeated layer by layer until the build is complete.

When the build finishes, an initial brushing is manually administered to parts to remove a majority of loose powder, followed by the appropriate heat-treat cycle while still fixtured in the support systems to relieve any stresses. Parts are removed from the platform and support structures are removed from the parts, then finished with any needed bead blasting and deburring. Final DMLS parts are near 100 percent dense.

Vacuum Casting

Vacuum casting involves the use of a vacuum to pull liquid into silicone molds, thus making plastic or rubber parts. This process is also called urethane casting or polyurethane casting because polyurethane resin is the casting material. Because the process occurs under a vacuum, the resulting casts are bubble-free and have smooth surface textures with zero defects. 

The vacuum casting process is usually used for rapid prototyping as it is a faster and more economical option than other methods, including injection molding. This process is capable of producing components with intricate details using polyurethane resins. 

Used in the production of many fast-moving consumer goods and electronics, vacuum casting is excellent for producing premium quality parts in batches and small volumes within a short period. The parts created can be used for quality validation, pre-launch product testing, operation testing, designing concept models and prototypes, etc.

How Does Vacuum Casting Work?

Vacuum casting uses silicone molds, PU resins, and a vacuum chamber for resin casting to create superior parts or components. This process involves mold preparation, casting preparation, vacuum casting, resin infiltration, and curing and finishing.