Rapid product realization process

A process for designing and optimally fabricating a plastic object, comprising the steps of:

• creating a model of the object using a databank in a digital computer;
• defining a set of constraints for the object;
• determining an optimum path through a plurality of manufacturing processes using the defined set of constraints;
• selecting from the plurality of manufacturing processes those processes that lie on the optimum path and defining a precedence relationship between the selected processes to create a set of interconnected activities;
• transforming the databank into a second databank that contains information that is usable by each of the selected processes, and sending the information to each of the selected processes;
• and
• performing an activity at each selected process in accordance with the defined precedence relationship, whereby an output of the last one of the selected processes is the plastic object.

A rapid product realization process, comprising the steps of:

• creating a first computer databank representative of a surface model of the product, the databank containing information about the exterior of the product;
• translating the surface model into a solid model by processing the first databank to create a second databank that is a solid model of the product;
• fabricating a master part that is a physical representation of the product using a machine responsive to the second databank;
• fabricating a mold tool having a cavity representative of the product;
• and
• fabricating the product by filling the mold tool cavity with a plastic resin.

A rapid product realization process, comprising the steps of:

• creating a first computer databank representative of a surface model of the product, the databank containing information about the exterior of the product;
• translating the surface model into a solid model by processing the first databank to create a second databank that is a solid model of the product;
• fabricating a mold tool using a CNC machine or a stereolithography apparatus responsive to the second databank, the mold tool having a cavity representative of the product;
• and
• fabricating the product by filling the mold tool cavity with a plastic resin.

A rapid product realization process, comprising the steps of:

• creating a first computer databank representative of a surface model of the product, the databank containing information about the exterior of the product;
• translating the surface model into a solid model by processing the first databank to create a second databank that is a solid model of the product;
• adding information representative of internal features of the product to the second databank;
• fabricating a mold tool having a cavity representative of the product;
• and
• fabricating the product by filling the mold tool cavity with a plastic resin.

A rapid product realization process, comprising the steps of:

• creating a first computer databank representative of a surface model of the product by inputting information into a computer, the databank containing information about the exterior of the product;
• translating the surface model into a solid model by processing the first databank to create a second databank that is a solid model of the product;
• fabricating a mold tool having a cavity representative of the product;
• and
• fabricating the product by filling the mold tool cavity with a plastic resin.

A rapid product realization process, comprising the steps of:

• creating a first computer databank representative of a surface model of the product, the databank containing information about the exterior of the product;
• translating the surface model into a solid model by processing the first databank to create a second databank that is a solid model of the product;
• fabricating a mold tool having a cavity representative of the product;
• and
• fabricating the product by filling the mold tool cavity with a plastic resin by means of reaction injection molding or high pressure injection molding.

A process for rapidly realizing a product from concept to finished parts, comprising the steps of:

• creating a first computer databank representative of a surface model of the product, the databank containing information about the exterior of the product;
• translating the surface model into a solid model by processing the first databank to create a second databank that is a solid model of the product;
• fabricating a master part that is a physical representation of the product using the second databank to fabricate a master part using stereolithography or computer numeric controlled machining;
• fabricating a mold tool from the master part by casting a tool using room temperature vulcanizing silicone rubber or by flame spraying, the mold tool having a cavity representative of the product;
• and
• fabricating the product by injection molding plastic resin into the mold tool cavity.