What is Rapid Prototyping? Methods, Tools and Examples

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Rapid prototyping is a collection of techniques used to quickly fabricate a physical part or assembly from a three-dimensional design. With rapid prototyping, engineers and designers can create a better final product by iterating several times between digital designs and physical prototypes through a fast and cost-effective workflow.

Using rapid prototyping tools such as Formlabs' 3D printers, anyone can transform ideas into realistic proofs of concept, advancing these concepts to high-fidelity prototypes that closely resemble final products in both appearance and functionality. Best of all, 3D-printed prototypes are cost-effective, allowing teams to produce numerous affordable prototypes with quick turnaround times.

This guide presents real-life examples of rapid prototypes from leading companies. It will cover the fundamentals of rapid prototyping, its applications, and how 3D printing can facilitate the rapid and cost-effective development of prototypes.

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Rapid Prototyping vs Prototyping

Prototyping is a crucial element in the product development process, but traditionally, it has acted as a bottleneck.

Product designers and engineers typically create makeshift proof-of-concept models with basic tools. However, producing functional prototypes and production-quality parts often involves the same processes as finished products. Traditional manufacturing methods like injection molding require costly tooling and setup, making low-volume, custom prototypes prohibitively expensive.

In contrast, rapid prototyping enables companies to swiftly turn ideas into realistic proofs of concept, advancing these concepts into high-fidelity prototypes that look and function like final products, guiding products through a series of validation stages toward mass production.

With rapid prototyping, designers and engineers can create prototypes directly from digital models developed in CAD software more quickly than ever, allowing for quick and frequent revisions based on real-world testing and feedback.

3D Printing for Rapid Prototyping

A rapid prototype of a robot arm produced with 3D printing (left) alongside the final end-use assembly (right).

Since rapid prototypes are typically built with additive fabrication techniques as opposed to traditional subtractive methods, the term has become synonymous with additive manufacturing and 3D printing.

3D printing is an excellent fit for prototyping products, offering almost unlimited form freedom, no tooling requirements, and the ability to produce parts with mechanical properties closely resembling those made with traditional manufacturing methods. While 3D printing technologies have been available since the 1980s, their cost and complexity often limited their use to large corporations or forced smaller companies to outsource production, leading to long turnaround times.

With 3D printing, designers can rapidly move between digital designs and physical prototypes, speeding up the production process.

The rise of desktop and benchtop 3D printing has changed the landscape, inspiring widespread adoption that shows no signs of abating. In-house 3D printing allows engineers and designers to quickly iterate between digital designs and physical prototypes. It is now possible to create prototypes within a single day and perform multiple iterations based on the results of real-world testing and analysis. Ultimately, the rapid prototyping process helps companies bring better products to market faster than their competitors.

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Originally published on fastradius.com on April 21. Rapid prototyping (RP) refers to the fast fabrication of physical products using Computer-Aided Design (CAD) during the product life cycle's design phase. It can be utilized throughout the design process, from concept creation to final testing. Effective rapid prototyping assists engineers in avoiding potential pitfalls early on, improves a product's overall quality, and accelerates speed to market. It can also quickly reproduce complex geometries directly from a CAD file without the need for tooling.

There are two types of prototypes: low-fidelity and high-fidelity. Low-fidelity prototypes are rough mock-ups employed during the early design stages to help designers and engineers comprehend a concept's form and function, enabling rapid design improvements. High-fidelity prototypes are nearly exact representations of a final design, used to validate a product's performance, appearance, and ergonomics.

While rapid prototyping offers significant advantages of additive manufacturing, selecting the right type of 3D printing can be challenging. To assist in this process, we have outlined six of the most common methods for rapid prototyping.

Fused Deposition Modeling (FDM)

During Fused Deposition Modeling (FDM), a heated nozzle melts thermoplastic materials like polycarbonate or ABS within its barrel and extrudes the liquified material, layer by layer, following a specific toolpath. FDM has been in use for many years and is one of the most common prototyping technologies because it is easy, safe to use, and can produce relatively strong parts at moderately low cost.

However, FDM is not known for structural integrity, often resulting in parts that are porous, possess non-uniform strength, and have limited functional testing capabilities. Additionally, FDM is slower than stereolithography or selective laser sintering. Nevertheless, engineers should consider FDM a viable option during product development since it offers a cost-effective means for rapid prototyping.

Stereolithography (SLA)

Stereolithography (SLA) is the enduring rapid prototyping choice for many design and engineering teams. In this process, a computer-controlled UV laser traces each 2D slice of a part on the build platform, curing a liquid photopolymer resin. Each completed layer adheres to the previous one, and the cycle repeats until a complete part is formed. SLA is fast, affordable, and widely available. SLA prototypes are frequently utilized in medical devices and models.

Since SLA does not require engineering-grade resins, prototypes made via this process are typically weaker and unsuitable for rigorous testing. Moreover, UV light can degrade over time, particularly when exposed to humidity. Nonetheless, SLA parts exhibit a significantly better surface finish than FDM due to the higher resolution of the laser and reduced visibility of layer lines. Engineers should consider SLA for prototypes requiring intricate designs or superior surface quality.

Digital Light Synthesis (DLS)

Carbon's Digital Light Synthesis (DLS) employs a photochemical method to construct parts. Light is projected through an oxygen-permeable window into a vat of UV-curable resin. A digital device subsequently projects a sequence of UV images into the resin, causing the part to solidify layer by layer until the complete part is formed. The printed part is then cured in a forced convection oven, as the application of heat enhances the mechanical properties of DLS-printed parts.

This method is ideal for developing high-fidelity prototypes and small isotropic parts because the printing stage is continuous. Parts produced through DLS possess strength and mechanical properties comparable to those manufactured using injection molding. DLS is also compatible with various industrial-grade materials, making it perfect for numerous part iterations.

However, DLS is not the most suitable prototyping method for printing parts larger than a person's hand, and engineers may need to adjust their designs to accommodate this process's supports. Additionally, it is generally more expensive than other prototyping techniques and has a limited build volume.

Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS) uses a powerful computer-controlled laser to sinter multiple layers of powdered materials, predominantly nylon-based, into a solid form. Besides nylon, SLS accommodates elastomeric TPU powders resembling thermoplastics. This rapid prototyping technique is especially suitable for manufacturing automobile hardware parts.

Prototypes created with SLS are more robust, durable, and appropriate for functional assessments compared to those made with SLA. This method also offers greater versatility than SLA, as it can employ various materials while maintaining uniform strength. However, SLS parts tend to be porous, less detailed, pricier, and take longer to produce.

Multi Jet Fusion (HP MJF)

Multi Jet Fusion (HP MJF) is a powder bed technique that constructs 2D cross-sections by using inkjet heads to deposit a fusing agent onto a layer of powder, which is subsequently fused using an infrared lamp. The components are then removed from the build box and blasted to eliminate excess powder.

HP MJF is considerably faster than SLS, producing functional, chemically resistant, and highly dense prototypes in roughly a day. This makes it ideal for watertight applications, enclosures, and other prototypes involving complex assemblies. Prototypes can also be created in full color, allowing designers to evaluate a product's aesthetics. However, HP MJF is limited to PA12 nylon and may not guarantee high accuracy when creating small features.

PolyJet

During the PolyJet printing process, a print head deposits a layer of photopolymer resin onto a gel matrix and subsequently cures the resin with ultraviolet light. This technique produces ultra-thin and exceptionally smooth layers of material, offering a superior surface finish for prototypes. The print head can also eject droplets of various materials, enabling the creation of multi-material prototypes in a single print.

However, PolyJet shares many of SLA's vulnerability traits. Prototypes manufactured with this method are not very robust and may deteriorate due to UV sensitivity. Still, if engineers seek a rapid prototyping process compatible with numerous materials that yields an elegant, high-resolution print, PolyJet could be an appropriate option.

Build Better Prototypes with Expert Advice

Selecting the best rapid prototyping process can be daunting. By balancing budget restrictions, timelines, physical requirements, and other essential factors, engineers can narrow down the rapid prototyping method that best fits their project. Collaborating with an expert manufacturing partner can help guarantee an informed choice.

If you seek the ideal partner to enhance not only your rapid prototyping process but every stage of your manufacturing project, turn to SyBridge. Our expert team brings years of experience to the table, elevating your operations from concept to delivery, and ensuring you achieve a product of unmatched quality. Contact us today for a quote.