Rapid Prototyping
Build each prototype to answer the next product decision
A useful prototype does not need to copy the final product in every way. It must test the current assumption: size, handling, assembly, appearance, or early function.
Form prototype
Check proportions, geometry, and handling.
Fit prototype
Check holes, clearances, mating features, and installation.
Functional trial
Use a closer material and profile for early working tests.
Define the question
State what decision you will make after receiving the part.
- Pass when dimensions and proportion are correct
- Pass when assembly is neither tight nor loose
- Pass under a defined trial load
Choose prototype fidelity
Do not pay for properties the current round does not need to prove.
- PLA for many form and display checks
- PETG for tougher functional handling
- ASA when the trial involves outdoor exposure
Control revisions
File names and design changes should be traceable from the first round.
- Include a revision in the filename
- Identify what changed
- Record the result and decision from each round
Decision guide
Match prototype to question
| Type | What it proves | Approach |
|---|---|---|
| Form | Shape/size | Optimize speed and cost |
| Fit | Holes and assembly | State tolerance and mating part |
| Functional | Load/use | Match material and orientation to load |
| Presentation | Finish/appearance | Identify show faces and acceptable color |
Limitations to understand
- —An FDM prototype does not replicate every production material or process
- —Finish and tolerance must match the selected technology
- —One trial part is not a service-life certification
FAQ
Questions before submitting
Which material should I start with?
Start with the question. PLA often suits form checks; PETG, ASA, or a specific material may suit functional trials.
Should I print one part first?
Yes when the design is changing. One validated part reduces batch risk.
How complete must the file be?
It should be a closed mesh with correct units and size. Use a custom quote if no file exists yet.
Continue and start an assessment
Connect material, function, and ordering guidance before deciding.