A GUIDE TO

PROTOTYPING
FOR STARTUP
MANUFACTURERS
 A Guide to Prototyping for Startup Manufacturers

Introduction
For a startup manufacturer getting that first product right is

Contents crucial for your reputation and future sales. First impressions
really do count when you are building up your company and brand
equity.

Time is another critical factor as you strive to get a product to

02 Quick Reference Prototyping Process Comparison market and begin to generate revenue. Yet it is a mistake to skip
a thorough prototyping and testing programme because if you
03 Process Comparisons for Prototyping Options discover an error during manufacturer, the cost of putting it right
is far higher in money, time and reputation.
08 Choosing a Process It is far better to make any adjustments in design, material,
size, shape, colour, manufacturability and strength following
09 Summary testing and analysis. To balance this tightrope between testing
time and cost, it pays to understand all of the rapid prototyping
technologies that are available to you.

There are numerous ways prototypes can be made. Some

prototyping processes use traditional manufacturing methods.
Other technologies have emerged and have been improved upon
over a relatively short period of time. As prototyping processes
continue to evolve, the product designer is constantly trying to
determine what process or technology is best for their unique
application.

This technical brief explores the advantages and shortcomings

of the major prototyping processes available to designers. It
also describes the processes and discusses material properties
of parts produced by each. In addition, a helpful decision tree
highlights key questions designers must consider. Ultimately,
the goal of this paper is to help you select the best prototyping
process for your product development process.

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 A Guide to Prototyping for Startup Manufacturers

PROCESS DESCRIPTION STRENGTH FINISH EXAMPLE MATERIALS

3DP SL Laser-cured 2,500 - 10,000 (psi) Additive layers Thermoplastic - like photopolymers, true
Stereolithography photopolymer 17.2 - 68.9 (mpa) .025 - .100 (mm) silicon
typical
3DP SLS Laser-sintered powder 5,300 - 11,300 (psi) Additive layers Nylon, metals
Selective Laser Sintering 36.5 - 77.9 (mpa) .102 (mm) typical
3DP DMLS Laser-sintered metal 37,700 - 190,000 (psi) Additive layers Stainless steel, titanium, Cobalt chrome,
Direct Metal Laser Sinter- powder .020 - .060 (mm) aluminium, Inconel, copper
ing typical
3DP FDM Fused extrusions 5,200 - 9,800 (psi) Additive layers ABS, ABS/PC, PC, PPSU, Nylon, ASA, PLA
Fused Deposition Model- 35.9 - 67.6 (mpa) .127 - .330 (mm)
ling typical
3DP Liquid binder inkjet 7,200 - 8,750 (psi) Additive layers Acrylic-based photopolymers, elastomeric
Three Dimensional Print- printed onto powder 49.6 - 60.3 (mpa) .015 - .030 (mm) photopolymers
ing typical
3DP PJET UV-cured jetted 6,200 – 12,000 (psi) Additive layers Nylon, TPU, Nylon12 GF
Poly-Jet photopolymer 43 – 83 (mpa) .08 mm
3DP MJF IR lamp sintered powder Low Additive layers Plaster-based powder/liquid binder
Multi Jet Fusion with liquid agents .089 - .203 (mm)
typical
CNC Machined using 3,000 - 20,000 (psi) Subtractive machined Most commodity and engineering-grade
Computer Numerically CNC mills 20.7 - 137.9 (mpa) (smooth) thermoplastics and metals
Controlled (Machining)
IM Injection moulded using 3,100 - 20,000 (psi) Moulded smooth (or Most commodity and engineering-grade
Injection Moulding aluminium tooling 21.4 - 137.9 (mpa) with selected texture) thermoplastics, metal and liquid silicone
rubber
VC A master part (3DP or 2,900 – 8,700 (psi) Smooth, glossy or Most common plastics like ABS, PP, PE,
Vacuum Casting CNC machined) is used 20 – 60 (mpa) matt PMMA, PC, Nylon, rubber
to create a silicone
mold. NO we don’t use thermoplastics for
Vacuum casting. Only Thermoset resins

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 A Guide to Prototyping for Startup Manufacturers

3D Printing - SL Stereolithography
SL is an additive fabrication process that builds parts in a pool of UV-curable photopolymer resin using a computer-controlled laser. The laser is used to trace out and cure a
cross-section of the part design on the surface of the liquid resin. The solidified layer is then lowered just below the surface of the liquid resin and the process is repeated. Each
newly cured layer adheres to the layer below it. This process continues until the part is completed. SL was the first ‘rapid prototyping’ technology.

Pros Cons
For concept models or patterns to be used as masters Prototype parts are not as strong as those made from
for other prototyping methods, SL can produce parts engineering-grade resins, so the parts made using SL
with complex geometries and excellent surface finishes are normally unsuitable for functional testing. Also,
when compared to other additive processes. If you need since the resin is UV-curable, exposure to sunlight
micro resolution features then there are materials, continues to cure the resin and parts can become brittle
such as MicroFineTM Green and MicroFineTM Grey, over time.
that can achieve features down to 0.07mm (in X-Y
direction) using SL. The cost is very competitive and the
technology is available from several sources.

3D Printing - Selective Laser Sintering (SLS)

The SLS process uses a laser to build parts by sintering (fusing) powdered material layer by layer from the bottom up. SLS parts can be accurate and more durable than SL
parts, but the finish is relatively poor with a grainy or sandy feel. Though SLS parts are fairly strong, there is reduced strength between the fused particles, so the parts will
tend to be weaker than machined or moulded parts made from the same resin. Nylon-based materials are currently the primary resins available.

Pros Cons
SLS parts tend to be more accurate and durable than SL The parts have a grainy or sandy texture and are
parts. The process can make durable parts with complex typically not suitable for functional testing due to their
geometries. reduced mechanical properties.

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 A Guide to Prototyping for Startup Manufacturers

3D Printing - Multi Jet Fusion (MJF)

Multi Jet Fusion uses an inkjet array to selectively apply fusing and detailing agents across a bed of nylon powder. This is then fused by heating elements
into a solid layer. After each layer, powder is distributed on top of the bed and the process repeats until the part is complete.

Pros Cons
MJF offers engineering grade materials with great While the surface quality is good, it is rougher than
overall properties. Additionally, MJF offers an that produced by photopolymer-based technologies
enhanced surface finish, fine features, consistent (Stereolithography). The raw parts are grey, which
mechanical properties, and fast build times. can be dyed but this is an extra process.

Direct Metal Laser Sintering (DMLS)

Direct metal laser sintering is an additive manufacturing technology that produces metal prototypes and production-quality parts. DMLS uses a laser system
that draws onto a surface of atomised metal powder. Where it draws, it welds the powder into a solid. After each layer, a blade adds a fresh layer of powder
and repeats the process. DMLS can use most alloys, allowing prototypes to be a full-strength, functional part made out of the same material as production
components. It also has the potential, if designed with manufacturability in mind, to transition into metal injection moulding for when you need to increase
production.

Pros Cons
DMLS produce strong (typically, 97 percent dense) If producing more than a few DMLS parts, costs
prototypes from a variety of metals that can be can rise. Due to the powdered metal origin of the
used for functional testing. Since the components direct metal process, the surface finish of these
are built layer by layer, it is possible to design parts are slightly rough.
internal features and passages that could not be
cast or otherwise machined.

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 A Guide to Prototyping for Startup Manufacturers

3D Printing - Fused Deposition Modeling (FDM)

The FDM process builds parts from the bottom up through the use of a computer-controlled print head. The feedstock for the process is a filament of
extruded resin, which the machine selectively re-melts and deposits on the prior layer for each cross section of the desired part. FDM primarily produces
parts in ABS or PC, so they tend to be stronger than parts from other additive processes. However, the parts are sometimes porous and have a pronounced
stair-stepping or rippling texture on the outside finish, especially at layer junctions. It may also be difficult to achieve tight tolerances with the process.

Pros Cons
FDM parts are relatively strong and can be good The parts have a poor surface finish, with a
for some functional testing. The process can make pronounced rippled effect. It is also a slower
parts with complex geometries. additive process than SL or SLS for build time.

3D Printing - PJET PolyJet

PJET uses inkjet heads to jet a UV-curable material in very thin layers at high resolution. The materials are jetted in ultra-thin layers onto a build tray,
layer by layer, until the part is completed. Each photopolymer layer is cured by UV light immediately after it is jetted. The gel-like support material, which is
specially designed to support complicated geometries, is easily removed by hand and water jetting.

Pros Cons
This process yields a good surface finish; one of the PJET parts have poor strength (comparable to
best of the additive processes. It is a good additive SL). While PJET can make parts with complex
choice for complex parts with undercuts. The geometries, it gives no insight into the eventual
process can make parts with complex geometries. manufacturability of the design.

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 A Guide to Prototyping for Startup Manufacturers

3DP - Three Dimensional Printing

In 3DP an inkjet print head moves across a bed of powder, selectively depositing a liquid binding material, and the process is repeated until the complete part has been
formed. After completion, the unbound powder is removed leaving the finished object.

Pros Cons
3DP offers one of the fastest build times of any Parts are rough and weak, and there are very few
additive process, and is also among the least material options. While 3DP can make parts with
expensive options for prototype quantities. Coloured complex geometries, it gives no insight into the
models can communicate more information and have eventual manufacturability of the design.
aesthetic appeal. This plaster material is non-toxic,
inexpensive and readily available. The process can
make parts with complex geometries.

IM - Injection Moulding
Rapid injection moulding works by injecting thermoplastic resins into a mould, just as in production injection moulding. What makes the process ‘rapid’ is the technology
used to produce the mould, which is often made from aluminium instead of the traditional steel used in production moulds. Moulded parts are strong and can have
excellent finishes. It is also the industry standard production process for plastic parts, so there are inherent advantages to prototyping in the same process if the
situation allows. Almost any engineering-grade resin can be used, so the designer is not constrained by the material limitations of the prototyping process. Additionally,
metal injection moulding (MIM) and liquid silicone rubber (LSR) moulding offer rapidly moulded parts in metals like stainless steel and LSR, respectfully. There is an
initial tooling cost associated with rapid injection moulding that does not occur with any of the additive processes or with CNC machining. So, in most cases, it makes
sense to do one or two rounds of rapid prototypes (subtractive or additive) to check fit and function before moving to injection moulding.

Pros Cons
Moulded parts are made from an array of engineering Front-end costs can be higher due to tooling costs.
grade materials, have excellent surface finish and are
an excellent predictor of manufacturability during the
production phase.

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 A Guide to Prototyping for Startup Manufacturers

CNC Machining - Computer Numerically Controlled Machining

A solid block of plastic or metal is clamped into a CNC mill and cut into a finished part through a subtractive process. This method produces superior strength
and surface finish to any additive process. It also has the complete, homogenous properties of the plastic because it is made from solid blocks of extruded or
compression moulded thermoplastic resin, as opposed to most additive processes, which use plastic-like materials and are built in layers. The range of material
choices allows parts to be made with the desired material properties, such as: tensile strength, impact resistance, heat deflection temperatures, chemical resistance
and biocompatibility. Good tolerances yield parts suitable for fit and functional testing. Prototypes can be delivered in days just like additive processes. Because the
process involves removing material instead of adding it, milling undercuts can sometimes be difficult. Machining also tends to be somewhat more expensive than the
additive processes.

Pros Cons
Machined parts have a good surface finish and they There are some geometry limitations associated with
are very strong because they use real engineering- CNC machining, and it is much more expensive to do
grade thermoplastics and metals. this in-house than the additive processes due to the
cost of the programmers and machinists needed to
create CNC toolpaths and fixturing for the parts.

VC - Vacuum Casting
The process starts with making a mould by encapsulating a master model in two-part liquid silicone rubber. A vacuum is then applied to remove any trapped air,
then it is cured in an oven. Master models can come from a number of 3D printing technologies including stereolithography.
Vacuum casting allows the production of small batches of high quality mouldings in a range of polyurethane resins that replicate the performance of engineering
plastics without the high costs of hard tooling associated with injection moulding.

Pros Cons
Vacuum casting can be used for small batches of Rapid wear of the mould, only used for a few dozen
high quality prototypes or low volume end use parts. parts.
A wide range of resins are available and master
models can come from a range of sources, the most
common being stereolithography models. Good
dimensional stability.

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 A Guide to Prototyping for Startup Manufacturers

Choosing a What stage are you at in

the prototyping process?
What factor(s) is/are most
important to you?
Recommended attributes to
consider when choosing a process.

Process STAGES FACTORS ATTRIBUTES

Use the decision tree to the right
Quantity
to narrow down which factors are Complexity
Speed
of highest importance to you Concept Model
Material Choice
based on where you are in the Appearance
Surface Finish
prototyping process, referring as Colour
needed to the definitions following
this decision tree infographic. Material Choice
Complexity
Form Colour
Assembly/Fit Test
Fit Material Choice
Tolerance
Material Stability
Chemical Resistance

Mechanical Properties Material Choice

Quantity
Functional Testing Electrical Properties Speed
Complexity
Thermal Properties Tolerance

Optical Properties
Material Choice
Material Stability
Mechanical Properties Quantity
Life Test
Speed
Aging Properties (UV, Creep)
Complexity
Tolerance
Flammability Properties

EMI/RFI Properties Material Choice

Regulatory Testing
Speed
Food Rating

Bio-compatibility

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 A Guide to Prototyping for Startup Manufacturers

ATTRIBUT SL SLS MJF DMLS FDM 3DP PJET IM CNC VC

Quantity

Complexity

Surface Finish

Material Selection

Material Stability

Colour

Tolerance

Speed

Price- Low Volume

Price- High Volume

Poor Fair Good

Useful glossary of definitions and terms Electrical Properties – interaction of electrical fields and the part. This may include EMI/RFI Properties – the ability of a resin, part or assembly to shield or block
dielectric constant, dielectric strength, dissipation factor, surface and volume resistivity, Electromagnetic Interference or Radio Frequency Interference.
You will come across a number of different terms in prototyping, testing and static decay, etc. Food Rating – approval of a resin or part to be used in applications where it will come in
manufacturing. Unfortunately, definitions of what is meant by a term or material property Thermal Properties – changes in mechanical properties that occur with changes contact with food while it is being prepared, served or consumed.
can vary between organisations, but we believe that the list below is a good starting point. in temperature. These may include thermal expansion coefficient, heat deflection Bio-compatibility – the ability of the resin or part to be in contact with human or animal
Concept Model – A physical model made to demonstrate an idea. Concept models allow temperature, vicat softening point, etc. bodies, outside or inside the body, without causing undue adverse effects (e.g. irritations,
people from different functional areas to see the idea, stimulate thought and discussion, Optical – ability to transmit light. May include refractive index, transmittance and haze. blood interactions, toxicity, etc.). Bio-compatibility is important for surgical instruments
and drive acceptance or rejection. Life Test – testing properties that may change with time and that are important for a and many medical devices.
IMPORTANT PROTOTYPING ATTRIBUTES: product to remain functional throughout its expected life. Life testing often involves
Speed – turnaround time to convert a computer file into a physical prototype. subjecting the product to extreme conditions (e.g. temperature, humidity, voltage, UV, etc.)
Appearance – any visual attribute: colour, texture, size, shape, etc. to estimate in a shorter period of time, how the product will react over its expected life.
Assembly / Fit Test – making some or all of the parts of an assembly, putting them Mechanical Properties – fatigue strength: ability to withstand large numbers of load cycles
together, and seeing if they fit properly. At the gross level, this checks for design errors, at various stress levels.
such as placing two tabs at 2 in. spacing and the mating slots at 1 in. spacing. At the fine Aging Properties (UV, creep) – ability to withstand exposure to ultraviolet light with an
level, this is a matter of minor dimensional differences and tolerances. Obviously, any test acceptable amount of degradation; ability to withstand extended applications of forces to
involving tolerances needs to use the actual manufacturing process or one which has the part with acceptable levels of permanent deflection.
similar tolerances. Regulatory Testing – testing specified by a regulatory or standards organisation or agency
Form – the shape of the part: features and size to assure parts are suitable for a particular use such as medical, food service or consumer
Fit – how the part mates with other parts. application. Examples include; the International Standard Organisation (ISO), the European
Commission (EC), Underwriters Laboratory (UL), the Canadian Standards Association
Functional Testing – seeing how a part or assembly will function when subjected to
(CSA), the US Food and Drug Agency (FDA) and the US Federal Communications
stresses representing what it will see in its actual application.
Commission (FCC).
Chemical Resistance – resistance to chemicals including acids, bases, hydrocarbons, fuels,
Note “Regulatory Testing” above is very US focused – any other European agency
etc.
examples?
Mechanical Properties – strength of the part measured by tensile strength, compressive
Flammability Properties – the resistance of a resin or part to ignition in the presence of a
strength, flexural strength, impact strength, tear resistance, etc.
flame.

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 A Guide to Prototyping for Startup Manufacturers

Conclusion
Prototype models help you make more informed In order to most effectively validate your design, is, it will go nowhere if you can’t manufacture it.
decisions by obtaining invaluable data about pay close attention to these three key elements of Make sure your prototyping process takes this into
performance. The more data that you gather at your design: consideration.
this stage of the product development cycle, the • functionality
better the chances of preventing potential product • manufacturability Finally, even if your prototype design is functional
or manufacturing issues down the road. If a well • viability and manufacturable, it doesn’t mean anyone
thought out prototyping strategy is followed, there If your prototype can faithfully represent the will want to use it. Prototypes are the only true
is a far greater chance that the product will be attributes of the end-product, it is by definition way to verify the viability of the design in this
introduced to the market on time, be accepted, functional. These requirements often include sense. If your design can also pass the challenges
perform reliably and be profitable. such things as material properties (e.g. flame associated with market trials (e.g., trade show
resistance), dimensional accuracy for fit-up with displays, usability testing) and regulatory testing
What is the best way to get a prototype made? mating parts and cosmetic surface finishes for (e.g., FDA testing of medical devices), then you’re
The answer depends on where you are at in your appearance. well on your way to a successful product launch.
process and what you are trying to accomplish.
Early in the design process, when the ideas are If you can repeatedly and economically
flowing freely, concept models are very helpful. produce your prototype design that supports
As the design progresses, a prototype that has the requirements of the end product, then it is
the size, finish, colour, shape, strength, durability manufacturable. These requirements include
and material characteristics of the intended final the ability to maintain the functionality of the
product becomes increasingly important. Therefore, design as described above, keep the piece-part
using the right prototyping process is critical. cost below the required level, and support the
production schedule. No matter how great a design

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