Prototyping with 3D printing: from the first model to the near-series prototype

In prototyping with 3D printing, prototypes are produced directly from the 3D data – without tooling and usually within a few days. This lets you test shape, fit and function early, implement changes quickly and move into series production with a validated design.

On the PROTIQ Marketplace, you will find the right process for every phase: more than 160 materials and more than 12 processes from more than 40 suppliers – from the visual model to the prototype made of the series material. You upload your file, compare the offers and decide for yourself. PROTIQ is itself one of the suppliers.

• Prototype types
• Benefits
• Iteration
• Ordering
• From prototype to series
• Examples
• FAQ

• 40+ supplierson the PROTIQ Marketplace
• 160+ materialsplastics and metals
• 12+ processes3D printing and other manufacturing processes
• no toolingcost-effective from a quantity of one

Prototype types

Which types of prototypes are there – and which process fits?

Depending on the development phase, a prototype needs different properties: a design model should look like the later product, a functional prototype must withstand loads, and a near-series prototype should behave like the series part. The right process differs accordingly.

Not every process can be selected directly in the configurator. Select it in the configurator or request it from us.

Not sure? The process guide and the Material Finder help you decide.

Benefits

Why produce prototypes with 3D printing?

Conventionally manufactured prototypes require a lot of planning, often tooling and subsequent adjustments. 3D printing produces directly from the 3D data. This shortens the planning and production phase and makes every design change quick to implement.

Functional prototypes made of plastic

Selective laser sintering (SLS) produces mechanically resilient parts made of technical plastics. Typical examples are housing parts and fixtures that can even include functional elements such as living hinges and snap-fit hooks. For electronics applications, there is, for example, electrically dissipative PA11 ESD.

Too delicate to print? At PROTIQ as a supplier, overly delicate areas in 3D models are thickened and thus made printable for SLS.

Functional prototypes made of metal

Industrial components are expected to perform more and more functions while becoming smaller and lighter. This leads to complex structures with honeycombs and struts, conformal cooling channels or a stress-optimized, organic design. Selective laser melting (SLM) produces such parts in metal – with very good mechanical properties.

Iteration

How does prototyping work?

Prototyping is an iterative process: produce a prototype, test it, evaluate feedback, adapt the 3D model – until the design meets the requirements. The shorter each cycle, the faster the product is ready for the market.

1. Develop the 3D modelThe first draft is created in CAD. Simulations show early on whether the design works.
2. Produce the first prototypeThe prototype does not have to be perfect – it is the starting point for tests and feedback.
3. Test and adaptTests and user feedback show where improvements are needed. The changes go into the 3D model and the next prototype.
4. Move into series productionOnce the prototype meets the requirements, the series product is manufactured.

What does the iterative approach offer?

• Early error detection: Problems are identified and fixed before they become expensive.
• User-centered design: Regular feedback ensures that the product meets the actual requirements.
• Flexibility: New insights can be taken into account at any time.
• Cost and time efficiency: Step-by-step improvements avoid delays caused by major design errors.

Virtual prototypes and simulation

CAD programs and simulations show how structure, function and ergonomics behave even before the first physical prototype. Changes to the 3D file are much faster than changes to the finished object. Simulation does not replace physical testing – but it reduces the number of loops.

Tips on creating printable data can be found under How to create a 3D file.

No 3D data available?

Your prototype or part already exists, but not as a 3D file? Using reverse engineering with computed tomography (CT), we create 3D data of your object for further processing and future production.

Request reverse engineering

Ordering

Ordering prototypes on the PROTIQ Marketplace

Upload your 3D file in the configurator, choose material and quantity and compare the suppliers’ offers with price and delivery time. You decide for yourself where to order.

1. Upload your 3D fileUpload your model in the configurator.
2. Choose material and processFilter by material, process and properties.
3. Compare offersYou see the suppliers’ prices and delivery times, with several delivery time options depending on the supplier.
4. OrderYou pay the selected price; the part is manufactured by the supplier of your choice.

Practical for teams and purchasing

• Save and share your cart: Configured carts can be saved and passed on to colleagues or purchasing, who can then place the order.
• Binding PDF quote: Create a binding quote as a PDF from the cart – for internal approval, for example.
• PROTIQ Purchase: Source parts from different suppliers and still have only one contractual partner – the invoice comes from PROTIQ.
• Project inquiry: For complex projects or processes that cannot be selected directly, start a project inquiry.

Upload your file now

From prototype to series

From prototype to series

The closer the prototype is to the series part, the more meaningful the tests. With 3D printing, prototypes can also be made from series materials – and many parts can go straight on into small-batch production.

• Prototypes made of the zinc die-casting material: PROTIQ processes Zamak 5 in 3D printing – for functional prototypes with the material properties of the later die-cast part, without any die-casting tool.
• Small batches without tooling: Processes used for prototypes are often also suitable for small batches and low-runners. Find out more under Series production.
• Large series: For large quantities of plastic parts, injection molding is usually the more economical solution. This is also possible via the PROTIQ Marketplace.
• Precise functional surfaces: Printed parts can be selectively post-processed by CNC machining.

Examples

Prototyping examples

PA12 housings

Resilient housings and fixtures in laser sintering – with living hinges and snap-fit hooks.

More about PA12

Copper inductors

Optimized coil shapes for induction heating, produced by laser melting.

More about copper inductors

Zamak 5 prototypes

Functional prototypes made of the zinc die-casting material – without a die-casting tool.

More about Zamak 5

3D printing and CNC

Printed parts with CNC-machined functional surfaces.

More about CNC machining

FAQ

Frequently asked questions about prototyping with 3D printing

What is prototyping with 3D printing?

In prototyping with 3D printing, visual models and functional samples are produced directly from digital 3D data – without tooling. It is a key application of additive manufacturing and supports the early phases of product development in particular.

What are the benefits of 3D printing in prototyping?

Short production times, high design freedom and fast iterations. Changes are made directly to the 3D model and implemented without additional tooling. Several variants can be produced in parallel.

What types of prototypes can be produced with 3D printing?

From concept and design models through geometric and functional prototypes to near-series prototypes. Depending on material and process, the parts are mechanically resilient, temperature-resistant or have near-series properties.

Which process is suitable for my prototype?

For design models with fine details and smooth surfaces, SLA or PolyJet are suitable, for example; for resilient functional prototypes made of plastic, SLS or Multi Jet Fusion; for metal prototypes, laser melting (SLM). The process guide and the Material Finder help you decide – or write to us.

Can I have prototypes made of the series material?

For some materials, yes. One example is Zamak 5: PROTIQ processes the zinc die-casting material in 3D printing, producing functional prototypes with the properties of the later die-cast part – without a die-casting tool.

What if my 3D model is too delicate?

At PROTIQ as a supplier, overly delicate areas in 3D models are thickened and thus made printable for selective laser sintering (SLS).

I only have a physical part – how do I get 3D data?

Using reverse engineering with computed tomography (CT), PROTIQ creates 3D data of your existing object, which can then be further processed and manufactured.

How quickly will I receive a prototype?

Prototypes are usually produced within a few days. The exact delivery time depends on the process, material and supplier and is shown directly in the offer comparison.

How much does a 3D-printed prototype cost?

The price depends on factors such as part size, material, process and quantity. After uploading your 3D file, you will see the suppliers’ offers in the configurator; you pay the selected price.

Which industries is 3D-printed prototyping suitable for?

3D-printed prototypes are used in many industries, including mechanical and plant engineering, electrical engineering and electronics, and consumer goods development.

More information

• Upload your file now
• Process guide
• Material Finder
• Series production
• Zamak 5 in 3D printing
• Technical articles for download