Prototyping
What is rapid prototyping, and how do you do it well?
Rapid prototyping is making physical test parts quickly from CAD, most often by 3D printing, to check form, fit and function before tooling. Work in stages: cheap form models first, functional parts next and production-material parts last, with each stage answering one question. On our service, the fastest turnaround is 1 calendar day.
Reviewed by HenleyPrint3D engineers2 min readUpdated
Key takeaways
- Match the prototype to the question: fit, function or appearance.
- Fastest turnaround is 1 calendar day.
- Change one thing per iteration.
- Switch process only when the question changes.
Suits
Product and mechanical engineers iterating a design towards production.
Worth knowing
Each prototype answers one question. Judge strength only on parts made in a production-like material.
Which prototype answers which question?
| Question | Prototype | Suggested process |
|---|---|---|
| Does it fit and look right? | Form model | FDM in PLA or PETG |
| Does it work under load? | Functional part | FDM nylon or ASA; SLS nylon |
| Does it look like the product? | Appearance model | SLA or PolyJet, finished and painted |
| Will it survive production use? | Pre-production part | Production material and process |
Rapid prototyping key figures
| Figure | Value |
|---|---|
| Fastest turnaround | 1 calendar day |
| FDM build volume | Up to 1000 × 1000 × 1000 mm |
| SLA tolerance minimum | ±0.1 mm |
| Production batches | Same machines and set-up as prototypes |
Working through the stages
Start with the cheapest model that answers your first question. A form model in PLA or PETG tells you whether the part fits and looks right, and it can be in your hands from 1 calendar day. Move to nylon or ASA when you need to test under load. Move to SLA or PolyJet when the part must look like the product.
To match a process to each stage, see how to choose a 3D printing process. To order prototypes, see our rapid prototyping service.
Frequently asked questions
What is rapid prototyping?
Rapid prototyping is the fast production of physical parts from CAD to test form, fit and function before tooling or production. 3D printing is the most common method, alongside CNC machining and casting.
How long does rapid prototyping take?
Simple FDM and SLA parts can be ready from one calendar day on our service and SLS from two, with finishing and quantity adding time. Complex finishing or multi-part programmes take longer.
Is 3D printing the best method of rapid prototyping?
It is usually the fastest and most economical for complex, low-quantity parts. CNC machining may be better for tight tolerance or metal parts, and casting for small batches in production-like plastics.
How much does a prototype cost?
Cost depends on size, volume, process, material and finishing. Small FDM parts are the cheapest, followed by SLS, SLA and PolyJet. Request a quote with your CAD for an exact price.
How many prototypes will I need?
Most products need two to five iterations at each stage, but it varies with risk and complexity. Testing several variants in parallel usually reduces the elapsed time.
Get started
Talk to an engineer about your part.
Send us your CAD or describe the problem. We recommend the process, material and finish, and quote with the lead time up front.
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