Rapid prototyping: a prototype in a few days

Why prototype

Everything looks fine on screen until you hold the part in your hand. Rapid prototyping appeared in the 1980s and replaced weeks of waiting for tooling and moulds. A physical prototype shows whether the part fits in the assembly, whether it feels right in the hand, whether the holes are in the right place and whether you like the shape. A mistake found on a prototype costs a few euros, and one found in a production mould costs thousands.

What a good process looks like

1. You design the part in CAD software, for example Fusion or FreeCAD.
2. You print a first version and check the dimensions and the joints.
3. You adjust the model, allow for tolerances, and print a second version.
4. Once the shape is final, you decide on the production method.

First versions do not have to be perfect. For shape and dimensions, light infill is often enough, which saves time and money. For a strength test, though, choose the material you plan to use in the final part.

Prototypes with us

You upload a model (STL, 3MF, OBJ or STEP, up to 50 MB) and immediately see the price per part and the delivery. You choose the strength: light infill 10 %, standard 15 %, strong 40 %. The materials are PLA for quick shape samples and PETG for parts that have to cope with bending or damp. The maximum size of a single part is 246 × 246 × 256 mm. If the prototype proves itself, you can go straight on to order a small batch of up to 5,000 parts.

We do not do any finishing on the surface or dimensions after printing, so bear that in mind for prototypes of precise assemblies.

What to check on a prototype

• Dimensions. Measure the critical points and compare them with the drawing.
• Assembly. Try fitting the part with the others, including screws and joints.
• Ergonomics. Pick it up and use it the way it will be used.
• Strength. Load it and see where it breaks. Usually it is along the layers, see delamination.

Write down what needs to change, adjust the model and print a second round. Several small rounds are usually cheaper than one big mistake in production.