Why should your business consider 3D printing services and prototyping for your new product design? Conventional prototyping methods, which involve techniques like injection molding and mock-ups, may take weeks (if not months) to create just one iteration. When the finished prototype is ready, every revision will require just as intense a process as the previous model. Remember that the expenses for each unit quickly add up as well. Prototyping a product design is traditionally a long process, but newer technology like additive manufacturing methods can help reduce the time and budget to a significant degree.
Additive manufacturing also comes in many different techniques, but the most widespread of them all is 3D printing design services. As the name says, technology transforms a drawn design into a physical object. 3D printing is a digital fabrication method using materials like plastic and metals. Depending on the complexity of the design, the printing process can take hours to complete, but it is still faster than most alternatives. Popular 3D printing filament includes durable nylon, acrylonitrile butadiene styrene (ABS), powder metals, and polylactic acid (PLA).
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Some plastic materials are reinforced with high-strength components such as carbon fiber. Without additional components, polycarbonate (not to be confused with acrylic or plexiglass) is one of the strongest plastic filaments. When printing a metal prototype, the filament is usually mixed with binders; it does require post-processing, such as sintering (to remove the binder), but the result is as dense and rigid as cast metal. There are also more “playful” filaments, for example, glow-in-the-dark, wood-filled, clay/ceramic, dichromatic, conductive, and color-changing.
While 3D printing offers many applications, it is mostly used by rapid prototyping firms. A wide range of material selections and fast production turnaround make the technology an excellent choice. Also, the relatively low-cost initial investment allows everyday inventors and small startups to get their prototypes ready without draining their wallets. By definition, additive manufacturing refers to the fabrication method in which a material is added – usually layer by layer – until it forms the desired shape. There are several types depending on the level of accuracy and details required:
- Fused deposition modeling (FDM): 3D printer with FDM technology is the most affordable option. It uses thermoplastic filaments, heated to the melting point, and then extruded to form the shape layer by layer. FDM 3D printer is suitable for home use.
- Stereolithography (SLA): unlike FDM, a stereolithography 3D printer uses liquid resin to help achieve the desired shape. UV light will harden each printed layer until the prototype is fully formed. The price is higher than FDM, but the result is much more accurate. It is best for prototyping a high-resolution plastic model.
- Selective laser sintering (SLS): 3D printers of which the filament is made of powdered materials. Layer by layer, the printed object is sintered to form a solid model. SLS is more expensive than SLA and FDM, and well-funded companies commonly use it to print high-quality product design prototypes.
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Either FDM or SLA should yield acceptable results for the early prototyping phase. You can use the printer to create a simple mock-up of jewelry design, architectural model, and product parts. Although 3D printing technology is excellent for (rapid) prototyping, it is not meant as a tool for mass production.
3D Printing advantages
Some of the most commonly cited benefits of 3D printing:
- Speed: among all the other advantages, speed is where the technology shines. 3D printing is a vital component in product design services and the prototyping creative process to manufacture proof-of-concept and get quick evaluation during the early design phase. The printed model is not always functional but allows designers to refine and adjust the approach quickly.
- Multi-component design: although 3D printing is most often utilized in the proof-of-concept prototype, high-end printers can manufacture intricate and complex mechanical parts. With individual filaments like metal or reinforced plastic, designers can achieve aesthetics and functionality close to the final product.
- High-fidelity models: a company can handle the entire prototyping phase of a product design using only one 3D printer. Designers can create everything from simple block models to high-fidelity functional beta prototypes.
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A prototype usually starts as a basic shape to confirm product dimensions and validate ideas. Once the initial concept is approved, the freelance design for assembly services builds increasingly complex models and experiments with multiple iterations. The most viable design option then gets refinements and improvements during the final stages of development. High-end 3D printers like SLA and SLS are well-equipped to manufacture a functional prototype. It also saves time and money because the process is done in-house.
Regarding plastic-based filaments, some of the best 3D printers on the market are priced at $400 to $2,500. Most of them are categorized as consumer-grade or for small business use. If the prototype has to be made of metal material, the 3D printers sit at an entirely different price bracket. For example, the Markforged Metal X is available for an affordable cost of around $90,000. One of the priciest is Desktop Metal Production System, costing more than a million.
The good thing is that plenty of options are positioned between the lowest and highest prices. Depending on your business and prototyping needs, sometimes affordable 3D printers with the right features can serve you better than their budget-demanding counterparts.
| Type of 3D printer | Price range |
|---|---|
| Plastic-based filaments (Consumer-grade/Small Business) | $400 – $2,500 |
| Metal Material (mark forged metal X) | Around $90,000 |
| Metal material (desktop metal production system) | More than $1,000,000 |
Please note that the price ranges provided are approximate and may vary based on specific models and market conditions.
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Why 3D printing prototypes
A prototype is essentially a work-in-progress – an early version of a product needing improvements; this is why prototyping rarely involves creating just a single model. The process often requires multiple iterations until it becomes near-identical to the finished product. 3D printing services offer the right technology for prototyping because it allows product designers to build custom models quickly and at a relatively low cost. There is also a wide range of material options for every purpose.
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Whether you run a small prototyping shop in a garage or a larger-scale custom manufacturing business, 3D printers are the right tools for the job for many reasons:
Limitless iterations
The term “limitless” might be a bit of an exaggeration here, but the principle applies. 3D printers have what it takes to create any number of prototype iterations, but it is not mass-manufacturing equipment. The object (prototype) starts as a 3D model drawn on a computer, and the 3d product modeling designer can change the image as the development continues and have the new iteration printed within hours.
Every 3D printer has its limits. If the CAD model is too complex with many intricate details, you may also need a better-equipped printer. You can theoretically make the prototype using consumer-grade print, but the results are likely less than stellar.
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Cost-efficient
Additive manufacturing is much more cost-efficient than conventional prototyping methods like injection molding. You don’t have to create the mold, yet the results are accurate to the CAD model. Since most 3D printers are reasonably compact (or at least office-friendly) and pretty much automated, a business doesn’t need to set up a dedicated room or hire specialized technicians to operate the equipment.
Time-saving
Printing time depends on the size and complexity of the object, and the printer’s specification also plays a crucial role. For example, a simple block model created on a mid-range 3D printer may take no more than several hours to complete, and the timeframe increases as the details get more complex. Also, it is a time-saving prototype manufacturing process because any company can do it in-house.
Functional prototypes
High-end 3D printers can use metal filaments and rigid materials such as carbon and glass fiber for products with internal mechanisms comprised of such components, metal 3D printers offer a quick method to build functional prototypes. Only a few metal filaments are available at the moment, including 316 stainless steel, copper, tool steel, aluminum, and Inconel.
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3D printing services
Acquiring an advanced 3D printer might be a financial burden for small businesses, but it is not the only option for additive manufacturing. Rapid prototyping is an industry flooded with specialized prototype design professionals ready to fulfill your prototyping needs. Some prototyping designers specialize in architectural designs, but many have various services, including product designs. They are not manufacturers in the traditional sense of the word but small-scale factories that “print” physical prototypes. The basic process is simple: you send the CAD file and have it made.
Most 3D printing services will make the prototype “as is,” meaning they fulfill the order and ship the model to you. It is fine as long as you know what to expect regarding quality. Looking for an experienced 3D print design expert to guide you through the process and assess the CAD file is best. Based on the analysis, they will recommend the correct printing technique to achieve the desired shape.
Utilizing 3D printing services, one can explore a range of material options, each with varying costs. Standard resin or nylon, for instance, are affordable choices, typically priced between $20 and $30. In contrast, premium metal materials, such as 316 stainless steel, command a steeper price, averaging around $900. Alongside material selection, both the intricacy of the design and the desired delivery timeline contribute to shaping the project’s overall cost.
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The cost of 3D printing materials is typically calculated based on the amount of material used for a specific 3D print, measured by weight or volume, and then multiplied by the cost per unit of material. For example, the cost of a 3D printed model would be determined by the estimated material usage (as calculated by slicer software) and then multiplied by the cost per kilogram or per cubic centimeter of the material.
| Material | Approximate Cost |
|---|---|
| Plastic-based (e.g., standard resin or nylon) | $20 – $30 |
| Metal (e.g., 316 stainless steel) | Around $900 |
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Summary
3D printing and prototyping have revolutionized product design by offering a more efficient and cost-effective way to create and iterate prototypes. Traditionally, prototyping has been a lengthy process, but additive manufacturing professionals nowadays use methods such as 3D printing that significantly reduce the time and budget required. 3D printing transforms digital designs into physical objects using various materials, including plastics, metals, and composite filaments. The technology allows for rapid prototyping, and with high-end 3D printers like SLA and SLS, functional prototypes can be manufactured in-house. However, acquiring an advanced 3D printer may be costly for small businesses.
As an alternative, companies can utilize specialized 3D printing services that offer various material options, each with different costs. Material choices range from affordable options like standard resin or nylon (approx. $20-$30) to premium metal materials like 316 stainless steel (approx. $900). The cost is determined by the material’s weight or volume and the complexity and size of the design. With 3D printing services, businesses can access various material options, receive guidance on the best printing technique, and achieve high-quality prototypes without investing in expensive equipment.
How Cad Crowd can help
Cad Crowd offers a network of experienced 3D printing experts who can help guide you through prototyping and ensure your design vision becomes a reality. Get a free quote today from Cad Crowd to explore the possibilities of 3D printing and prototyping for your product design.