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3D printing for prototypes
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Contents:
- Introduction
- What are the advantages of 3D printing prototypes?
- How to 3D print prototypes
- What materials should you choose to 3D print your prototypes?
Introduction
What are the advantages of 3D printing prototypes?
Create various iterations
3D printing gives you more freedom than any other manufacturing technique. As your object is created from a digital 3D model, using a 3D modeling software, you can easily create all the designs you want, from the most simple to the most intricate ones. It is possible to create any project from scratch, get a good visualization, and to adjust your 3D model whenever you want to.
Thanks to 3D printing, you can give life to your 3D model by printing it to create a prototype or even a final product. But let’s focus on the prototyping process: 3D printing is really convenient as you don’t have to create a whole mold for each iteration of your project. You are free to make different iterations, so the prototype can perfectly match your expectations for the final product.
Save money
Compared to traditional manufacturing techniques such as injection molding, additive manufacturing is much cheaper. But why? First, as we’ve just said, when using 3D printing, you don’t have to create a mold to create your object, which is a significant advantage. Time and money are precious for your company, that is why 3D printing is helping you to go straight to what is essential to you.
Save time
With 3D printing, you can do as many iterations as you need. Moreover, the process itself is quite faster. Instead of the creation of the mold and waiting for the whole injection molding process, additive manufacturing skips these steps. This manufacturing technique is perfect for rapid prototyping and can help you accelerate your whole product development.
Run tests with functional prototypes
Thanks to the variety of 3D printing materials now available on the market and our online 3D printing service, it is possible to access advanced materials. While many materials are adapted for production, they can also be used for your prototyping process. Indeed, if you need to run tests, these materials will allow you to make the most of the impressive properties to manufacture advanced functional prototypes.
How to 3D print prototypes
Are you ready to use additive manufacturing to develop your prototypes, but you don’t know how? Using an external 3D printing service is the perfect solution.
If you are looking for the most cost-effective technique to manufacture your prototypes, it is clear that investing in professional 3D printers is not part of your plan, and desktop printers leave much to be desired in terms of quality. Using a service such as Sculpteo will give you access to industrial technologies and materials, but you will also benefit from the advice of our 3D printing experts. They will help you implement 3D printing in your strategy and answer all your questions.
It is important for us to help our customers to improve their manufacturing process and their whole prototyping process to get the best products in the end. We have a 3D printing solution for all kinds of projects, from models for architecture to prototypes for mechanical parts, there is a material on our 3D printing service that will meet your expectations.
The process is simple: once your 3D model is ready, you just need to upload your 3D file on our platform, you will get an instant quote and receive your 3D printed prototype in a few days! But before that, here are the first steps you need to take in order to successfully 3D print your prototypes.
What materials should you choose to 3D print your prototypes?
What do you have to check first?
While using an online 3D printing service such as Sculpteo to improve your prototyping process, you can access a wide range of materials and technologies, with different properties and prices. But while choosing your material for prototyping you will have to check various aspects.
The price
It is certainly the most important point for your company. How to reduce costs but still improve your manufacturing process? For example, if you need to create a metal object, making your prototype with plastic will be quite interesting. Indeed, it would be more cost-effective to begin the early prototypes with plastic and then shift to metal 3D printing for the final validation. Choosing among the different plastic materials and the various options will help you to find the most economical solution for your prototyping project.
The accuracy and the quality of the material
A prototype is a way to get a perfect overview of the project to spot the last problems.
You certainly want to create a functional prototype. That is why, if you have a complex project or an object with an elaborated design, be sure to check that the material and 3D printing technique is precise enough to help with your prototyping process. However, you obviously have to keep in mind the mechanical properties of the final material that you will use.
With the right material, you should be able to manufacture a functional object. Do you need to get an object with the same weight as your final product? With the same dimensions? Able to have the same applications? You will have to ask yourself several questions before you make the final choice, in order to see all the aspects of your prototype that you need to check.
The design guidelines of the material
All materials have different design guidelines. While choosing your material, be sure to check them, to get a perfect object. It could be a reason why your 3D file is not 3D printable, you really have to be sure that everything is ok regarding the dimension and the geometry of your project.
Indeed, if the wall is too thin, the file could be non-printable or could break in no time, which would be counterproductive.
The best materials to 3D print your prototypes at Sculpteo
The choice of your 3D printing material really depends on your project. Here is a selection of our most used materials for prototyping projects! Plastic materials are obviously the cheapest solution for this stage of your product development; let’s see what you can do with them.
- Nylon PA12
This white plastic material is one of the most affordable materials with a lot of great mechanical properties. This material is made from fine polyamide powder, and is perfect for both prototyping and production. It will create your parts thanks to the Selective Laser Sintering technology.
If you choose this material for your prototyping project, you will see that you will have the choice between various options and finishes, but you can also get raw parts. Prototyping with Nylon PA12 (plastic) is a good solution because this 3D printing material is one of the cheapest options, so you will be able to make many iterations with a resistant material, that gives you a lot of freedom in terms of geometry.
- Multi Jet Fusion PA12
Our Multi Jet Fusion PA12 is a grey plastic. This material is perfect both for prototyping and production and its raw version is clearly the cheapest option you will get! It will allow you to make many iterations at a lower cost. The objects printed with this material are well suited against scratches and abrasion, which could be great to make tests. It is also light stabilized, U.V. stabilized and stable to weather, which is perfect if you need to make an experiment in outdoor conditions.
- Prototyping resin
This resin is specifically developed to prototypes and is well suited for non-functional prototypes. Indeed, if you need to manufacture highly detailed parts this material will be the perfect option. Prototyping resin offers a smooth surface finish, quite similar to objects manufactured using plastic injection molding. This resin is 3D printed using the Stereolithography (SLA) process.
- PLA
Fused Deposition Modeling techniques are particularly useful in the development of prototypes. Using this option, you will not get the most detailed prototypes. However, for some oversized project, this technique can be interesting. Indeed, at Sculpteo, we are using BigRep 3D printers to 3D print our PLA filament, allowing to print parts with the maximum size of 1 x 1 x 1 m.
- TPU
You need a really flexible plastic for your 3D printing project? TPU will be the perfect solution for you. This rubber-like material has a high elasticity and a high strength. That could perfectly fit your project if you need something really flexible for fully functional prototypes. As this material creates parts really resistant to stress and fatigue, it can even be used for your final products. Think about it! On our online 3D printing service, you will have the opportunity to choose between two TPU: Ultrasint® TPU01 and Ultrasint® TPU 88A.
- 3D printing metal for your prototypes ?
If you are planning to create 3D printed prototypes with metal materials, you have to know that it is totally possible but that it is not the most economical option for you.
However, we recommend you to use our Ultrafuse 316L Stainless Steel if you need to manufacture metal prototypes. This affordable material is printed using FDM technology; it is resistant and can be used to run tests of functional prototypes.
Binder jetting technology, can also be used to print your prototypes parts, with Steel / Bronze 420SS/BR and Stainless Steel 316.
Keep in mind that Direct Metal Laser Sintering is also used to make prototypes for the aerospace industry using Titanium 6AI-4V but is not a cost-efficient method for prototypes. It’s good to know if you have such projects, but most of the time, plastic will be used as the most convenient material for prototypes.
We hope that this article helped you to understand all the benefits and possibilities offered by additive manufacturing to develop prototypes. Do you have more questions about these materials? Feel free to contact our sales team for more information.
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Metal 3D Printing Service for Custom Parts
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E: [email protected]Best-in-Class Online Quoting
After uploading your part design, you'll receive an online quote that includes manufacturing analysis to help improve part manufacturability. Within your quote, you can also adjust quantity and material and see price changes in real-time.
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Jump to Section→ Capabilities
→ Available Alloys
→ Compare Material Properties
→ Surface Finishes
→ Post-Processing
→ Why Metal 3D Printing?
Direct metal laser sintering (DMLS) is an industrial metal 3D printing process that builds fully functional metal prototypes and production parts in 7 days or less.
A range of metals produce final parts that can be used for end-use applications.
Metal 3D printing technology is commonly used for:
- Prototyping in production-grade materials
- Complex geometries
- Functional, end-use parts
- Reducing metal components in an assembly
We hope you find this guide helpful. If the file did not download, you can find it here.
Metal 3D Printing Guide
Jump start your metal 3D printing with this guide that covers material selection, design, post-processing, and quality inspections.
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Metal 3D Printing Capabilities
Our basic guidelines for metal 3D printing include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.
Metal 3D Printing Tolerances
For well-designed parts, tolerances of +0.003 in. (0.076mm) plus 0.1% of nominal length can typically be achieved. Note that tolerances may change depending on part geometry.
Max Dimensions
Layer Thickness
Minimum Feature Size
Tolerances
*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine
Metal 3D Printing Material Options
Below is our available metal alloys for 3D printing.
Various heat treatments are available depending on material.
Stainless Steel (17-4 PH)
Stainless Steel 17-4 PH is a precipitation hardened stainless steel that is known for its hardness and corrosion resistance. If needing a stainless steel option, select 17-4 PH for its significantly higher tensile strength and yield strength, but recognize that it has far less elongation at break than 316L. Final parts built 17-4 PH receive vacuum solution heat treatment as well as H900 aging.
Primary Benefits
- Heat treated for full hardness and strength
- Corrosion resistance
LEARN MORE>
Stainless Steel (316L)
Stainless steel 316L is a workhorse material used for manufacturing acid and corrosion resistant parts. Select 316L when stainless steel flexibility is needed; 316L is a more malleable material compared to 17-4 PH. Final parts built in 316L receive stress relief application.
Primary Benefits
- Acid and corrosion resistance
- High ductility
LEARN MORE>
Aluminum (AlSi10Mg)
Aluminum (AlSi10Mg) is comparable to a 3000 series alloy that is used in casting and die casting processes.
It has good strength -to-weight ratio, high temperature and corrosion resistance, and good fatigue, creep and rupture strength. AlSi10Mg also exhibits thermal and electrical conductivity properties. Final parts built in AlSi10Mg receive stress relief application.
Primary Benefits
- High stiffness and strength relative to weight
- Thermal and electrical conductivity
LEARN MORE>
Inconel 718
Inconel is a high strength, corrosion resistant nickel chromium superalloy ideal for parts that will experience extreme temperatures and mechanical loading. Final parts built in Inconel 718 receive stress relief application. Solution and aging per AMS 5663 is also available to increase tensile strength and hardness.
Primary Benefits
- Oxidation and corrosion resistance
- High performance tensile, fatigue, creep, and rupture strength
LEARN MORE>
Cobalt Chrome (Co28Cr6Mo)
Cobalt Chrome (Co28Cr6Mo) is a superalloy is known for its high strength-to-weight ratio.
Primary Benefits
- High performance tensile and creep
- Corrosion resistance
LEARN MORE>
Titanium (Ti6Al4V)
Titanium (Ti6Al4V) is a workhorse alloy. Versus Ti grade 23 annealed, the mechanical properties of Ti6Al4V are comparable to wrought titanium for tensile strength, elongation, and hardness. Final parts built in Ti6Al4V receive vacuum stress relief application.
Primary Benefits
- High stiffness and strength relative to weight
- High temperature and corrosion resistance
LEARN MORE>
Compare Material Properties
20 μm = high resolution (HR)
30, 40, and 60 μm = normal resolution (NR)
- US
- Metric
| Materials | Resolution | Condition | Ultimate Tensile Strength (ksi) | Yield Stress (ksi) | Elongation (%) | Hardness |
|---|---|---|---|---|---|---|
| Stainless Steel (17-4 PH) | 20 μm | Solution & Aged (H900) | 199 | 178 | 10 | 42 HRC |
| 30 μm | Solution & Aged (H900) | 198 | 179 | 13 | 42 HRC | |
| Stainless Steel (316L) | 20 μm | Stress Relieved | 82 | 56 | 78 | 90 HRB |
| 30 μm | Stress Relieved | 85 | 55 | 75 | 88 HRB | |
| Aluminum (AlSi10Mg) | 20 μm | Stress Relieved | 39 | 26 | 15 | 42 HRB |
| 30 μm | Stress Relieved | 50 | 33 | 8 | 59 HRB | |
| 40 μm | Stress Relieved | 43 | 27 | 10 | 50 HRB | |
| Cobalt Chrome (Co28Cr6Mo) | 20 μm | As Built | 182 | 112 | 17 | 39 HRC |
| 30 μm | As Built | 176 | 119 | 14 | 38 HRC | |
| Inconel 718 | 20 μm | Stress Relieved | 143 | 98 | 36 | 33 HRC |
| 30 μm | Stress Relieved | 144 | 91 | 39 | 30 HRC | |
| 30 μm | Solution & Aged per AMS 5663 | 208 | 175 | 18 | 46 HRC | |
| 60 μm | Stress Relieved | 139 | 83 | 40 | 27 HRC | |
| 60 μm | Solution & Aged per AMS 5663 | 201 | 174 | 19 | 45 HRC | |
| Titanium (Ti6Al4V) | 20 μm | Stress Relieved | 153 | 138 | 15 | 35 HRC |
| 30 μm | Stress Relieved | 144 | 124 | 18 | 33 HRC |
| Materials | Resolution | Condition | Ultimate Tensile Strength (MPa) | Yield Stress (MPa) | Elongation (%) | Hardness |
|---|---|---|---|---|---|---|
| Stainless Steel (17-4 PH) | 20 μm | Solution & Aged (H900) | 1,372 | 1,227 | 10 | 42 HRC |
| 30 μm | Solution & Aged (H900) | 1,365 | 1,234 | 13 | 42 HRC | |
| Stainless Steel (316L) | 20 μm | Stress Relieved | 565 | 386 | 78 | 90 HRB |
| 30 μm | Stress Relieved | 586 | 379 | 75 | 88 HRB | |
| Aluminum (AlSi10Mg) | 20 μm | Stress Relieved | 268 | 180 | 15 | 46 HRB |
| 30 μm | Stress Relieved | 345 | 228 | 8 | 59 HRB | |
| 40 μm | Stress Relieved | 296 | 186 | 10 | 50 HRB | |
| Cobalt Chrome (Co28Cr6Mo) | 20 μm | As Built | 1255 | 772 | 17 | 39 HRC |
| 30 μm | As Built | 1213 | 820 | 14 | 38 HRC | |
| Copper (CuNi2SiCr) | 20 μm | Precipitation Hardened | 496 | 434 | 23 | 87 HRB |
| Inconel 718 | 20 μm | Stress Relieved | 986 | 676 | 36 | 33 HRC |
| 30 μm | Stress Relieved | 993 | 627 | 39 | 30 HRC | |
| 30 μm | Solution & Aged per AMS 5663 | 1434 | 1207 | 18 | 46 HRC | |
| 60 μm | Stress Relieved | 958 | 572 | 40 | 27 HRC | |
| 60 μm | Solution & Aged per AMS 5663 | 1386 | 1200 | 19 | 45 HRC | |
| Titanium (Ti6Al4V) | 20 μm | Stress Relieved | 1055 | 951 | 15 | 35 HRC |
| 30 μm | Stress Relieved | 993 | 855 | 18 | 33 HRC |
These figures are approximate and dependent on a number of factors, including but not limited to, machine and process parameters.
The information provided is therefore not binding and not deemed to be certified. When performance is critical, also consider independent lab testing of additive materials or final parts.
Surface Finish Options
Standard Finish
Expect roughness values of 200 to 400 µin Ra (0.005 to 0.010mm Ra), depending on material and resolution. Support structures are removed and layer lines are visible.
Custom Finish
We offer brushed surfaces in a range of grits and polished mirror finishes. Be sure to indicate if the custom surface finish is for functional or aesthetic purposes so we can best consult you on our custom options.
Post-Processing Capabilities for Metal 3D-Printed Parts
Improve strength, dimensional accuracy, and cosmetic appearance of final metal components with DMLS for production.
Surface Finishing
- 3- and 5-axis milling
- Turning
- Polish (Mirror or Brushed)
- Passivation
- Wire EDM
- Tapping and reaming
Heat Treatments
- Stress relief
- NADCAP heat treatment
- Hot isostatic pressing (HIP)
- Solution annealing
- Aging
Mechanical Testing
- Tensile
- Rockwell Hardness
Powder Analysis & Material
- Traceability
- Chemistry
- Particle size and distribution analysis
Why Use Metal 3D Printing?
See how metal additive manufacturing technology can be used to reduce components within an assembly, fabricate complex geometries, and ultimately save you time and costs.
Click to enlarge
How Does Metal 3D Printing Work?
The DMLS machine begins sintering each layer—first the support structures to the base plate, then the part itself—with a laser aimed onto a bed of metallic powder. After a cross-section layer of powder is micro-welded, the build platform shifts down and a recoater blade moves across the platform to deposit the next layer of powder into an inert build chamber. The process is repeated layer by layer until the build is complete.
When the build finishes, an initial brushing is manually administered to parts to remove a majority of loose powder, followed by the appropriate heat-treat cycle while still fixtured in the support systems to relieve any stresses. Parts are removed from the platform and support structures are removed from the parts, then finished with any needed bead blasting and deburring. Final DMLS parts are near 100 percent dense.
Large Format Metal 3D Printing
We recently added the GE Additive X Line to our fleet of metal 3D printers to build large Inconel 718 and Aluminum (AlSi10Mg) parts.
Have a project that might be a good fit? Contact us and we can discuss your requirements.
Learn More >
Metal 3D Printing for Production
Improve strength, dimensional accuracy, and cosmetic appearance for end-use metal components with post-processing options like CNC machining and heat treatments.
Learn More >
Resources
Design Tip
Post-Processing for Metal 3D Printing
Learn how to improve dimensional accuracy, surface roughness, and mechanical properties on metal parts with high-requirement applications.
Read Design Tip
White Paper
Combining Part Assemblies with Additive Manufacturing to Reduce Cost and Increase Performance
How to find the right opportunities to consolidate multi-part assemblies into single components with industrial 3D printing
Read White Paper
Blog
Inconel 718: A Workhorse Material for Additive Manufacturing
Inconel 718 is a go-to material for additive manufacturing of metal parts.
Read Blog
Blog
Large Format 3D Printing for Aluminum and Inconel Parts
When you’re printing really large parts in metal, it’s great to have a choice of materials. Aluminum and Inconel 718 both make a lot of sense, but which one is the best for your application?
Read Blog
Instant quotes on 3D-printed parts
Get A Quote3D printed prototypes for functional testing
Testing product prototypes, individual assemblies and parts is an essential part of any production chain. With 3D printing, you can quickly obtain high-precision and low-cost samples of future products for various tests and tests.
Which tests can you carry out on the received products:
- check the assembly for assembly;
- study the behavior of various materials in the working environment;
- test new design solutions;
- test strength, wear resistance;
- blow through objects in a wind tunnel.
Which tests can you carry out on the received products:
- check the assembly for assembly;
- study the behavior of various materials in the working environment;
- test new design solutions;
- test strength, wear resistance;
- blow through objects in a wind tunnel.
Benefits of functional prototyping with 3D printing
- Speed. You don't have to wait weeks for contractors to build a prototype for you.
- High precision. Test samples match your CAD model to within 15-20 microns.
- Low cost.
- Equipment versatility. With the help of 3D printing, you can get not only prototypes for tests, but also solve other production problems.
- Information security. Your know-how will not get to competitors if third-party contractors are not involved in the production chain.
Example: 3D printing for Nascar racing engines
Ford's Nascar racing team is actively using 3D printers to upgrade and test new engine, exhaust and fuel system components.
Thanks to 3D printing, our engineers have the unique ability to quickly get full-fledged prototypes of their designs, test them, make changes and implement them in our machines. This allows us to change the characteristics of cars incredibly quickly and prepare for the race.
Victor Martinez, Chief Engineer, Ford Team
Benefits of Functional Prototyping with 3D Printing
- Speed. You don't have to wait weeks for contractors to build a prototype for you.
- High precision. Test samples match your CAD model to within 15-20 microns.
- Low cost.
- Equipment versatility. With the help of 3D printing, you can get not only prototypes for tests, but also solve other production problems.
- Information security. Your know-how will not get to competitors if third-party contractors are not involved in the production chain.
Example: 3D printing for Nascar racing engines
Ford's Nascar racing team is actively using 3D printers to upgrade and test new engine, exhaust and fuel system components.
Thanks to 3D printing, our engineers have the unique ability to quickly get full-fledged prototypes of their designs, test them, make changes and implement them in our machines. This allows us to change the characteristics of cars incredibly quickly and prepare for the race.
Victor Martinez, Chief Engineer, Ford Team
Example: 3D printing a prototype stepper motor for testing
Example: 3D printing a prototype stepper motor for testing
Stratasys F370
Total-Z AnyForm 650 PRO
3DLAM Mid
UnionTech RSPro 800
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Stratasys F370
Total -Z Anyform 650 Pro
3DLAM MID
UnionTech RSPRO 9009
3D CREELIBICS, ADITALS - DDITITIONS OF IDITIONS OF THE DDITITIES worthwhile product without spending a lot of development resources.
3D prototyping is the ability to produce an object according to a drawing or mathematical model in full size or scale, without losing the main functions of the final product. When using metals, thermoplastics, polymer blends and composites, high quality and functionality can be achieved without resorting to classical production. Prototyping 3D models eliminates the risk of inaccurate design and engineering calculations and, consequently, unnecessary costs.
3D printing a model from a simplified (non-final) material or mass production material is the optimal solution for product development. You will be able to test a sample, check its functional properties and assembly compliance, make a presentation, and correct shortcomings even before the start of mass production.
Work stepsPrototyping typesTechnologiesPrices for 3D prototyping
Work steps
3D prototyping allows you to quickly start production in several basic steps: Testing the finished product, adjusting the digital model if necessary
With a prototype, you can appreciate its appearance, ergonomics, and even experience its functionality.
If the object meets the requirements of the company, it can be used as a master model or tooling for the first batch of goods - in DDM.Lab you can order the production of products by molding into silicone (from 10 to 1000 pieces) or single- or reusable production tooling.
Prototypes are most often ordered by large machine-building and instrument-making companies, developers of innovative products and designers interested in the speedy release of plastic and metal products. Leave a request, and our experts will select for you the best way to introduce additive technologies into production!
Types of prototypes
Conventionally, prototypes can be divided into several types:
- Industrial - created for large manufacturing enterprises (assemblies, housings, parts and spare parts)
- Transport - such prototypes are used in mechanical engineering, aviation, shipbuilding (from development to individual parts or components of land, water and air transport)
- Product prototypes allow you to work out the format of the future product and its packaging
- Presentation models, for example, a model of an apartment, a building or an entire city, make it possible to convey the project with its architectural features and interior design as clearly as possible.
for solving the problems of orthopedics, endoprosthesis, orthodontics.
Technologies
- FDM thermoplastic deposition modeling allows you to quickly and inexpensively produce fully functional samples of products and production tooling from a wide range of materials
- Inkjet printing with PolyJet photopolymers allows printing highly realistic color and multi-material products and tooling
- Selective laser fusion of LBM/SLM metals is often used for high-precision manufacturing of end products with complex geometry from metal-powder compositions of small fractions
- Gas-powder jet deposition using directed energy exposure DED/LMD is used for quick repair of worn surfaces of products, as well as for the manufacture of products from "scratch" from metal powder compositions
- 3DMP Arc Welding/Arc Wire Deposition - the most affordable and productive solution for the rapid production of high-stress end metal parts
- BJ inkjet printing by applying material powder and bonding it with a binder to create molds from sand-polymer compositions
- Selective SLS laser sintering for the rapid production of full-featured parts, production tooling from a wide range of polyamide and composite (polyamide-based) powders, and polystyrene powders for creating burnable master patterns for foundries
- SEAM screw extrusion hybrid additive manufacturing for rapid production of large-sized products using granular thermoplastics, including those filled with carbon fibers binder.
