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Prototype milling is a process where a three-dimensional CNC milling machine cuts a prototype model from various materials based on a digital model created by the design team. This process saves time and money during product development and allows designers to evaluate and demonstrate the product. The materials used vary depending on the expected level of detail and functionality.
Prototype milling is a machine manufacturing process used to build prototypes for design projects. The process involves cutting a prototype model from various materials using a three-dimensional computer numerical control (CNC) milling machine. These machines consist of a high-speed machine head capable of three-dimensional movements equipped with a spindle into which a set of cutting tool bits are inserted. The head moves over a block of model material, gradually peeling away layers from it until the finished prototype is revealed. The prototype milling process is controlled by one of several computer-aided design (CAD) programs on which a digital model of the prototype is built by the design team.
Prototyping is a product design process in which models of a proposed product are built prior to final product acceptance. This is a critical part of the design process that can save a significant amount of time and money during product development. Prototype models are built to include various levels of functionality, allowing designers to evaluate the product and demonstrate it to investors and the target market. Prototype milling is one of the processes commonly used to produce these models. It is known as the subtractive modeling method, as material is removed or subtracted from a modeling support block to produce the model.
The prototype milling process is performed by sophisticated three-dimensional CNC milling machines controlled by CAD programs. The process begins with the development of a three-dimensional digital computer model of the product. This model is used by a sophisticated CNC milling machine as a map to control its movement during the milling process. The machines feature nimble heads that drive high-speed cutting bits that closely follow the outline of the computer model, slowly cutting layers from a block of modeling material to reveal the finished prototype.
The materials used to mill the prototypes vary, but typically include various grades of epoxy, high-density foam, or metals. Specially designed wood sheets and laminates are also used in the production of prototype models. The choice of modeling material generally depends on the expected level of detail and the functionality the prototype is to exhibit. In some cases, the milled product will not be used as a prototype at all, but rather as a positive building block to create accurate molds used to produce high quality castings of the final prototype.
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