Done right, rapid prototyping streamlines product development, providing wholly positive results.
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Here is an example: Traditional prototyping for injection molding often involves new tooling and molds for each iteration, but creating multiple, expensive steel molds to test a part may not be the best use of this technology. Rapid prototyping aims to save you money by altering that step. One way is to use injection molding with comparatively inexpensive aluminum molds, or prototyping using 3D printing, CNC machining, or sheet metal fabrication, depending on your part design. With any of these, you’ll be able to manufacture your prototype at a fraction of the cost. Depending on your needs, your final iteration can then use injection molding for high-volume production.
Rapid prototyping typically involves digital manufacturing processes, which invite collaboration during the iteration phase, using a computer-based model of a part called a digital twin—a virtual version of a physical (or soon-to-be physical) part. The digital twin travels through a virtual version of the manufacturing floor, identifying potential manufacturability issues before the real work begins. Collective stakeholders can identify any issues in the digital version of the file, respond to that, and provide input before final manufacturing begins. Once a prototype has been manufactured, that physical object can be shared with others for their evaluation.
When prototyping, you want to use the fastest manufacturing method available to make your parts. That decision will be informed by your end part, but if you just need a part manufactured for which you can test form, fit, and function, it helps to choose the simpler/faster process to enhance iteration speed. As mentioned above, there are solutions that not only speed development, but also reduce costs.
Rapid prototyping allows for fast tweaks to design so you can customize the parts you need. Whether you intend to offer end users variations of color, material, or functionality, this method will speed manufacturing of individual parts for evaluation.
No one wants to go to full production quantities without proper testing and validation. At the core of rapid prototyping is a process that can detect flaws early in the development process, either via user feedback or functional testing. This can help avoid issues later in your product’s life cycle.
Something not often thought about is the fact that rapid prototyping gets you your parts faster. That reduces costs because you avoid the expense of waiting for parts and reduce go-to-market delays. Here are some additional ways to reduce costs:
Using a digital manufacturer moves your parts from CAD model to prototype faster than traditional manufacturers. It also has the bonus of offering design for manufacturing (DFM) feedback to ensure that your part doesn’t have issues that would prevent it from being manufactured.
Remember, it’s just a prototype. This isn’t your final part. Let’s say your final product needs to be made in an expensive material, such as titanium. If all you need is to confirm basic specifications and fit, any other metal (or in some cases, even plastics) will work well when evaluating part design.
Typically, these are aesthetic or protective coatings that simply are not necessary at this stage. Unless you need to validate the fit of a finished part within your application, eliminating finishes and other secondary operations such as smoothing on prototypes will save you money and time.
Think about the elements of each part that are most crucial to you and concentrate on nailing those down. Before prototyping, it helps to have a goal regarding what you would consider a minimum viable prototype (MVP). The MVP allows you to properly evaluate how your part works within the context of your application. Aim for that and you will likely have greater success more quickly.
Additive layers of 0.002-0.006 in. (0.051-0.152mm) typical, 0.004 in. (0.mm) maximum layer thickness
Thermoplastic-like photopolymers SLS Selective Laser Sintering Laser-sintered powder Additive layers of 0.004 in. (0.102mm) typical Nylon, TPU DMLS Direct Metal Laser Sintering Laser-sintered metal powder Additive layers of 0.-0. in. (0.020-0.030mm) typical Stainless steel, titanium, chrome, aluminum, Inconel FDM Fused Deposition Modeling Fused extrusions Additive layers of 0.005-0.013 in. (0.127-0.330mm) typical ABS, PC, PC/ABS, PPSU MJF Multi Jet Fusion Inkjet array selectively fusing across bed of nylon powderAdditive layers of 0.-0.008 in. (0.089-0.203mm) typical, only 0. in. (0.080mm) offered
Black Nylon 12 PJET PolyJet UV-cured jetted photopolymerAdditive layers of 0.-0. in. (0.015-0.030mm) typical, only 0. in. (0.030mm) layers offered
Acrylic-based photopolymers, elastomeric photopolymers CNC Computer Numerically Controlled Machining Machined using CNC mills and lathes Subtractive machined (smooth) Most commodity and engineering-grade thermoplastics and metals IM Injection Molding Injection-molded using aluminum tooling Molded smooth (or with selected texture), including industrial standard finishes such as SPI grades and Mold-Tech Most commodity and engineering-grade thermoplastics, metal, and liquid silicone rubber SM Sheet Metal Fabrication Conventional press brake sheet metal fabrication including permanent hardware, and welding Orbital sanded or straight grain brushed, and “#4” (304-#4 stainless) Aluminum, stainless, steel, copper, brass, and moreUse the decision tree below to narrow down which factors are of highest importance to you based on where you are in the prototyping process, referring as needed to the definitions below this decision tree infographic.
Definitions vary and may differ at different organizations, but the definitions below may be used as a starting point.
A physical model made to demonstrate an idea. Concept models allow people from different functional areas to see the idea, stimulate thought and discussion, and drive acceptance or rejection.
Manufacturing some or all parts of an assembly, putting them together, and seeing if they fit properly. At the gross level, this checks for design errors, such as placing two tabs at 2 in. (50.8mm) spacing and the mating slots at 1 in. (25.4mm) spacing. At the fine level, this is a matter of minor dimensional differences and tolerances. Obviously, any test involving tolerances needs to use the actual manufacturing process or one which has similar tolerances.
Evaluating how a part or assembly will function when subjected to stresses representative of what it will see in its actual application.
Testing properties that may change with time and that are important for a product to remain functional throughout its expected life. Life testing often involves subjecting the product to extreme conditions (e.g., temperature, humidity, voltage, UV light, etc.) to estimate in a shorter period of time, how the product will react during its expected life.
Testing specified by a regulatory or standards organization or agency to assure parts are suitable for a particular use such as a medical, food service, or consumer application. Examples include Underwriters Laboratory (UL), the Canadian Standards Association (CSA), the U.S. Food and Drug Agency (FDA), the U.S. Federal Communications Commission (FCC), the International Standard Organization (ISO) and the European Commission (EC).
As mentioned earlier, many engineers use 3D printing for prototyping and then switch over to injection molding for production quantities. It makes sense in terms of cost and time saved. Industries including aerospace and medical device typically take this path during their product’s life cycle. So, how do you set yourself up for success moving from 3D printing to injection molding? Here is a basic overview but note that we also offer more detailed information.
It is important to put a lot of thought into a part’s design, being cognizant of the different DFM requirements that 3D printing and injection molding have. During prototyping, don’t box yourself into a corner with fancy geometries that print beautifully but can’t be replicated via injection molding. Our interactive DFM feedback during quoting can provide helpful guidance.
Beyond that, consider the environment your parts will need to withstand. Choose designs and materials that can survive whatever will be thrown at them.
Designing and manufacturing multiple prototypes enables you to explore different design options, features, or aesthetic variations without committing to the costly tooling for injection molding too early. This allows for a more comprehensive understanding of what works best for the intended application and market. It also speeds up the period of time necessary to evaluate different iterations.
Transitioning to injection-molded parts requires specific design methods such as uniform wall thickness and draft angles. Maintaining a uniform wall thickness ensures the mold fills evenly, preventing defects. Adding draft angles to the design facilitates the easy ejection of the part from the mold. These are considerations that must be included when moving to injection molding, even if not present in a 3D-printed prototype.
Even the same material can act differently when printed vs. molded. Material selection for injection molding depends on various properties, including mechanical, physical, and thermal characteristics. Manufacturability, including resin flow and how well it fills the mold features, is essential. Cosmetic appearance and cost also play significant roles in the material selection process.
Prototyping using 3D printing is often the fastest way to iterate. Changes can be made in a CAD model, leading to quick turnaround of your updated prototype. While cost and deadlines are crucial factors, using affordable production methods can help control costs. Digital manufacturing can also accelerate product development, shortening both prototyping and production timelines. This approach helps optimize the overall efficiency of the transition from prototyping to production.
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Prototype models help design teams make more informed decisions by obtaining invaluable data from the performance of, and the reaction to, those prototypes. The more data that is gathered at this stage of the product development cycle, the better the chances of preventing potential product or manufacturing issues down the road. If a well thought out prototyping strategy is followed, there is a far greater chance that the product will be introduced to the market on time, be accepted, perform reliably, and be profitable.
What is the best way to get a prototype made? The answer depends on where you are in your process and what you are trying to accomplish. Early in the design process, when the ideas are flowing freely, concept models are helpful. As the design progresses, a prototype that has the size, finish, color, shape, strength, durability, and material characteristics of the intended final product becomes increasingly important. Therefore, using the right prototyping process is critical. In order to most effectively validate your design, pay close attention to these three key elements of your design: functionality, manufacturability, and viability.
If your prototype can faithfully represent the attributes of the end-product, it is by definition functional. These requirements often include such things as material properties (e.g., flame resistance), dimensional accuracy for fit-up with mating parts, and cosmetic surface finishes for appearance.
If your prototype design can be repeatedly and economically produced in a manner that supports the requirements of the end product, it is by definition manufacturable. These requirements include the ability to maintain the functionality of the design as described above, keep the piece-part cost below the required level, and support the production schedule. No matter how great a design is, it will go nowhere if it can’t be manufactured. Make sure your prototyping process takes this into consideration.
Finally, even if your prototype design is functional and manufacturable, it doesn’t mean anyone will want to use it. Prototypes are the only true way to verify the viability of the design in this sense. If your design can also pass the challenges associated with market trials (e.g., trade show displays, usability testing) and regulatory testing (e.g., FDA testing of medical devices), you’re well on your way to a successful product launch.
You already know that fast human insight is key to building a great customer experience. Whether you’re creating a website, mobile app, landing page, or other product, testing can happen at any stage of the design cycle. Despite this, many companies still begin the process of gathering customer insight much later than they should. No matter what you’re creating, prototype testing can—and should—happen early and often in your development cycle.
When it comes to prototyping you can test anything. Have an idea on a cocktail napkin? Test it. Not sure about product-market fit? Try it out on your target audience first. If ever there should be a cardinal rule to creating great experiences, it would be to test first, design and build after (then test again).
If you think it sounds odd to test something before it’s fully baked, you’re not alone. Many companies wait until their offering is fully developed before they test it, and suffer the consequences of rework, or worse, building something their customers don’t want.
Prototype testing enables you to assure that your design is going in the right direction and that you address any essential features or flaws before you write even one line of code. Redesigning a prototype is a lot easier—and less expensive—than reworking a finished product. You’ll save your budget and your sanity by testing right from the start.
No matter what stage you’re in, there are ways to create a prototype you can test. You can start with just a sketch on a post-it, or use one of the many prototyping tools available to bring your idea to life. Once you have your prototype ready, make sure you’re asking yourself these questions as you begin—and continue to—test.
The best way to think about prototypes is that they’re a representation of a finished product. Prototypes are a way for designers and developers to test the flow, interaction, content, and general feasibility and usability of a product before building and designing a fully-functioning product.
Or, for a more formal definition, here’s the Nielsen Norman Group’s perspective,
A user interface prototype is a hypothesis—a candidate design solution that you consider for a specific design problem. The most straightforward way to test this hypothesis is to watch users work with it.
Despite how much functionality or design a prototype may have, it’s not meant to be the final product. Some features won’t work, and the design and copy likely won’t be finalized. Prototypes are not intended to be pixel-perfect.
At this stage, you might have just an idea or the proverbial sketch on a cocktail napkin. When you’re in the very early days of your idea’s life, it’s totally OK to map out the idea with “low-tech” tools, like pen and paper. Not having a fancy interface doesn’t mean you can’t ask detailed questions, however. Here’s what you need to know during the early stages as you validate your concept:
If you need more inspiration to get started, check out our concept validation template below. Try our concept validation template
When you’re ready to move beyond the cocktail napkin, it’s time to start wireframing—this is when your ideas start taking their first steps. While these are not interactive or functional, they still illustrate the intention and flow, which is an essential process in the design phase.
Be sure you’re asking these questions to keep your project moving in the right direction:
If you need more inspiration to get started, check out our prototype evaluation template below.
Try our prototype evaluation template
Once you’ve worked through the kinks with the concept and design and iterated until you’re close, the hi-fi prototype is born. This will be a semi-functional facsimile of the intended result. It should be interactive and do pretty much everything it’s supposed to; it just won’t have the shiny new-product feel to it.
Focus on these questions to make sure you’re addressing any lingering concept, flow, or basic usability issues:
At this point, your cocktail napkin has grown up into a respectable, functional member of the community. While your testing days aren’t over, you’ve taken the important first steps that will save you time, money, and sanity by evaluating your idea from the start.
If you need help getting started testing high fidelity prototypes, check out our prototype evaluation template.
User testing a prototype is a bit different than testing a finished product. Make sure you inform test participants before the test—or even better, in the screening process—that they’ll be testing a prototype that’s not fully functional.
It’s also a good idea to run moderated tests if you can. While you can conduct unmoderated tests with prototypes, chances are your participants will have questions, and some tasks will require more explanation and guidance, so having a moderator present will help you get the best feedback.
If you are looking for more details, kindly visit rapid prototyping for robotics industry.