Rapid prototyping versus virtual prototyping in product design and manufacturing

Rapid prototyping (RP) is the production of a physical model from a computer model without the need for any jig or fixture or numerically controlled (NC) programming. This technology has also been referred to as layer manufacturing, material deposit manufacturing, material addition manufacturing, solid freeform manufacturing and three-dimensional printing. In the last decade, a number of RP techniques has been developed. These techniques use different approaches or materials in producing prototypes and they give varying shrinkage, surface finish and accuracy. Virtual prototyping (VP) is the analysis and simulation carried out on a fully developed computer model, therefore performing the same tests as those on the physical prototypes. It is also sometimes referred to as computer-aided engineering (CAE) or engineering analysis simulation. This paper describes a comparative study of the two prototyping technologies with respect to their relevance in product design and manufacture. The study investigates the suitability and effectiveness of both technologies in the various aspects of prototyping, which is part and parcel of an overall design and manufacturing cycle.