How To Manufacture a Prototype

Metal 3D printed turbine

Manufacturing a prototype is one of the early-stage steps in part production. Prototypes allow you to test your design before going to full-scale production and even allow you to test out different materials and assembly setups. 

The main role of a prototype is to move from a product idea to a physical product and this guide explores the most effective ways to manufacture prototypes, ensuring functionality, durability and manufacturability for your final product. 

What is a Prototype and Why is it Important?

3D printing early stage prototype

A prototype is a physical model of any idea, designed to refine the concept through the use of design iterations before mass production. It validates product performance, durability and aesthetics according to the designer specifications and product requirements. 

A product prototype is the closest form of a working prototype, which is almost the final product and validates the product design and functionality. Product prototypes are an integral part of the prototyping process because you can test the product in physical environments and replicate functional conditions. 

For example, a prototype can produce issues with heat resistance and structural integrity, enabling fixes before expensive production runs and production tooling. Working prototypes ensure the end product aligns with user experiences and market demands. 

Prototyping is part of the product development process. Different variations and types of prototypes act as checkpoints across stages of development. 

• Early stage prototypes
• Digital prototypes
• Low and high fidelity prototypes

Prototypes can also be created using computer aided design (CAD) and simulating prototype machining before production are a key part of rapid prototyping. Physical prototypes, such as CNC-machined metal prototypes or 3D printed

How to Make a Prototype Effectively?

Prototypes are fairly simple to make, considering you’ve already sketched your idea, creating a prototype requires a structured prototyping process and this is often a teamwork between different departments. 

You can find the steps to make a professional prototype that can help you accelerate the process of moving from prototype to production. 

Prototyping Process

Step-by-Step Prototyping Process

1. 1. Define Your Product Requirements: Product requirements can be taken from the application and the product’s performance criteria.
   2. Start With CAD Model: CAD software enables the production of 3d files, which can directly be used by CNCs and 3D printing technology for rapid prototype development. 

• Decide Manufacturing Technology: Depending on the material and part complexity, there are different prototyping technologies that can turn the digital prototype into a physical product. The most common is 3d printing prototypes.

• Prototype Making: Use CNC machines, 3d metal printing or DFM printers to produce prototypes

• Test and Validate Design: Post manufacturing, test your prototype by replicating real-world conditions and revise your design until the final prototype is ready.

Choosing the Right Materials for Your Prototype

Material selection is another critical part of prototype manufacturing. Materials can directly impact cost of prototyping, prototyping time and technology, and manufacturability. PLA is ideal for early-stage, non-functional prototypes, and ABS is more suited for a functional plastic product prototype due to its heat resistance and toughness. 

PLA

PLA is a cost-effective, biodegradable plastic used in 3D printing. It’s ideal for non-structural prototypes and early-stage prototypes due to its ease of printing and affordability. PLA is not durable, tough and can fail under rigorous functional testing. 

ABS

ABS is a tougher plastic and an extremely versatile material. It can be used for injection molding and 3D printing. Its durability and heat resistance make it suitable for testing at higher temperatures and loadings. ABS is more suitable for developing functional prototypes and can be used in consumer electronics and automotive parts.

Aluminum

Aluminum is a lightweight metal with high corrosion resistance and strength. Aluminum is mostly reserved for CNC-machined parts and developing products for aerospace or industrial applications. 

Tools and Technologies for Prototype Development

These materials can be used in additive manufacturing and CNC machining metal prototypes. 3D printing supports rapid prototyping and CNC machines can produce precision machined prototypes. 

CNC machining services like Prolean-Tech can also provide DFM support and highly specialied metal printing and injection molding prototyping. 

What are the Different Types of Prototypes?

CNC Machining for Metal Prototypes

Metal Prototypes

CNC machining can create precise prototype parts from metals like aluminum or stainless steel. Aluminum is often used in aluminum fabrication in prototyping due to its light weight and machinability. CNC-machined prototypes are ideal for functional testing and offer durability for many industries. 

3D Printing in Prototype Manufacturing

3D printing allows rapid prototyping of complex prototype designs. 3D printing is a cost-effective prototyping method for early-stage product development. It can fulfil dimensional and aesthetic validation, but lacks durability for functional prototypes. 

Vacuum Casting

Vacuum casted part

Vacuum casting produces low-volume functional prototypes using silicon molds. Vacuum casting can test the design and functionality of the prototypes. It’s fairly inexpensive and can balance cost and quality in production but it may not be suitable for high-quantity production runs.

Injection Molding

Injection molding

Injection molding is not the most preferable way of creating prototypes due to the high inital molding costs, but for intricate parts with many undercuts, overhangs and thin walls, injection molded parts can most closely replicate the final product. 

The advantage of injection molding prototypes is quickly moving to production if the prototype is validated, because the mold is already created. It is also ideal for low-volume prototyping and sending out prototypes to different people.

How to Transition from Prototype to Production?

Moving from prototype to production requires some key steps, specifically, for the manufacturing process to be scalable and to optimise production needs. 

Understanding the Production Process

It is crucial to validate the final prototype and involve feedback from both design and manufacturing teams to ensure the prototype is optimized for production scalability and quality control.. 

Ideally, a low volume production is always done before a full production run to send samples for market testing and avoiding costly manufacturing mistakes. 

Key Considerations for Mass Production

1. Optimize prototype design for the preferred manufacturing method. Look for prototyping partner with DFM support. 
2. Invest in high quality molds for part production
3. Reduce delays by optimizing the production process and following manufacturing procedures and standards. 
4. Check for quality assurance marks and stamps to make sure the end product meets reliability and performance standards set by different countries. 

How to Validate Your Prototype Before Mass Production?

The best way to check your prototype is through functional testing and dimensional measurements and user feedback to ensure it meets performance and usability requirements. You can validate prototypes this way to confirm reliability and performance. Test durability, form and aesthetics and even implement user feedback to refine your design. 

Another stage of prototype validation is by stress testing and load bearing which ensures the prototypes meets all standards required.

Overcoming Challenges in Prototype Development

Common Pitfalls in the Prototyping Process

• Overcomplicating designs: It’s not necessary to add all complex features on one face of the machining surface. Complex prototypes increase lead time. 
• Ignoring DFM practices: Your prototype design should follow DFM guidelines of your manufacturer to meet production needs and decrease costs
• Skipping tests: Without functional testing, your product can be delayed entry into the market or be recalled starting from phase 1 of product development. 

Managing Costs in Prototype Manufacturing

The easiest way to decrease costs and keep rapid prototyping under budget is by performing early-stage prototyping with 3D printing and delaying functional testing after meeting all feature and dimensional accuracies. 

You can partner with a rapid prototype manufacturer to reduce production costs and taking advantage of specialised machines for rapid lead times. 

Conclusion

Manufacturing a prototype is no longer a static process but a dynamic iterative development process, requiring expertise not only from designers but also from manufacturers in materials and processes. 

As a manufacturer you can take advantage of CNC machines and CAD software, to clearly translate your part drawings, dimensions and functionality to a skilled rapid prototyping expert. 

Rapid Prototyping Services

ProleanTech offers high-quality, rapid prototyping services to support your innovation from concept to production.

Contact us for fast lead times, engineering-grade materials, and exceptional manufacturing precision.

FAQ

• How do I manufacture a prototype?

You can manufacture a prototype by creating CAD model, choosing materials and using 3D printing or CNC machining to come up with a prototype for testing. 

• How much does it cost to manufacture a prototype?

Depending on the material and part complexity a simple prototype can cost anywhere from $100 to a few thousands. 

• How do I get my idea manufactured?

Sketch your idea and list your requirements. Use designer service or make your own 3D model and select a reliable prototype manufacturer and iterate your design. 

• What are the 5 steps in prototyping?

Define product goals, design a CAD model, select manufacturing method, build the prototype, test and refine for functionality

• how to make a prototype product?

To make a prototype product, you can start with listing your requirements and making a STL model of your part design. You can choose from many prototype manufacturing techniques but the most common are 3D printing and CNC machining. 

• how to manufacture a prototype?

You can use the skills and expertise of a prototype manufacturer to simplify the prototyping process and many manufacturers provide online quoting tools and emails for quick prototype quotes. 

• where to make a prototype?

You can make prototypes in China, where manufacturing is not only cheap but specialized forms of metal 3D printing and access to alloys and materials is easier.