Rapid Prototyping

Creating Prototypes with Rapid Prototyping

Many rapid prototyping operations employ additive manufacturing techniques (also known as 3D printing) to generate the desired physical parts, models, and/or assemblies. Compared to traditional manufacturing methods that attach separate materials together (e.g., welding) or remove excess material (e.g., machining), rapid prototyping involves the use of specialized materials—typically thermoplastics, metals, and photopolymers, that are heated, melted, and extruded to produce the pieces layer by layer.

Industry professionals often use this technique to make prototypes of new product design to test for manufacturability and functionality before proceeding to full-scale production. In addition to facilitating testing operations, prototypes allow for:

• Greater design flexibility. As the rapid prototyping process relies on CAD models, it does not necessitate investment in custom-designed tooling for each new part iteration. This process characteristic enables designers and engineers to adjust the part design and test it for functionality and manufacturability without having to invest in or wait on the production and delivery of new tools.
• Better visualization of the final product. Having a physical version of the prospective product can help designers and engineers catch and fix potential design flaws before the company invests time and money in a flawed or faulty final product.
• Clearer communication between team members and/or clients. Physical prototypes also make it easier for the design and engineering team to communicate with each other and their clients effectively. Rather than relying on abstract concepts or digital designs that can cause misunderstandings or misinterpretations, physical models make it possible for collaborators to visualize each other’s ideas.

All of these qualities facilitate more streamlined product development, enabling manufacturers to design, develop, and deliver their parts and products to market faster.

Due to the numerous advantages it provides to manufacturers, rapid prototyping finds application across a diverse set of industries, including in the following:

• Aerospace
• Automotive
• Consumer products
• Medical and dental
• Oil and gas