Rapid Prototyping Guide: Pros and Cons of Rapid Prototyping

Rapid prototyping is the process by which designers and engineers use 3D printing, sheet metal fabrication, CNC machining, or injection molds to quickly fabricate a model for a new product. The models can be high-fidelity prototypes (meaning they look and function very similarly to the end product) or low-fidelity prototypes (meaning they serve to test a specific function of a product).

For this testing method to be effective, each prototype needs to be inexpensive and quick to create so that developers can make changes for further improved prototypes. Rapid prototyping allows product developers to test physical products and tweak scale models until they are satisfied with the outcome.

In the world of apps, websites, and games, rapid prototyping allows developers to test out designs and simulations.

There are a few methods for rapid prototyping that you can use during the product design process.

1. 1. CAD software and 3D printing: Computer-aided design and 3D printing processes (and other additive manufacturing technology) revolutionized the world of rapid prototyping for physical products. Before 3D printing, manufacturers used subtractive manufacturing methods (like milling or grinding) or expensive CNC tooling to create prototypes—which was slow and prohibitively expensive. Now, thanks to 3D printers, manufacturers can create 3D model prototypes in CAD software and print them quickly and cheaply. These 3D printing technologies include cheap thermoplastic-based fused-deposition modeling (FDM), high-resolution stereolithography (SLA), binder jetting, selective laser sintering (SLS)/direct metal laser sintering (DMLS), selective laser melting (SLM)/direct metal laser melting (DMLM), and laminated object manufacturing (LOM).
2. 2. Paper prototyping: Paper prototypes are built with pencil, paper, scissors, and glue, making them an inexpensive rapid prototyping technique. You can create paper prototypes for products like board games, as well as designs for apps, websites, and video games. Paper models can help you figure out your visual layout and learn how to interact with your site or game. Even though it’s not digital, a paper prototype should test a specific concept or system—for instance, whether the currency system in your game works, or whether the sizing of images on your website feels natural. Unfortunately, paper models can’t test certain mechanics, like interactive websites or physics engines.
3. 3. Software prototyping: Code prototypes are built digitally, and they offer an avenue for testing apps, websites, and video games. When prototyping with code, you can tweak prototype parts that might affect user behavior—for instance, by changing the size of images on a website or adjusting the weight of objects a player interacts with in a game. Code prototyping takes time and effort, so use the most straightforward platform at your disposal, anticipate delays, and don’t get hung up on achieving perfection.

Rapid prototyping can make a huge difference when developing a product.

• It is inexpensive and fast. While other prototyping methods can be costly or slow, rapid prototyping is all about cheap materials and quick turnaround time. Rapid prototyping doesn’t require much labor, time, or money, which means that anything you learn from this testing method will be worthwhile.
• It allows you to test products thoroughly. Prototyping is essential for any product. You need to test each iteration to root out design flaws and discover ways to improve the look and performance of the end product. Rapid prototyping is a great way to test your product because you can tweak your product without worrying about time or cost.
• It encourages tweaks. The point of rapid prototyping is to create and test as many versions of your product as necessary. Rapid prototyping encourages you to make small tweaks to improve your product in whatever way you can. These small tweaks will help you make the best product possible.
• It helps predict future expenses. During rapid prototyping, you’ll learn about possible manufacturing difficulties and your product’s weaknesses in the early stages, and you can either correct them or plan around them. Without rapid prototyping, you may discover a flaw or challenge too late in the mass production process and have to make expensive corrections—or worse, recall the product entirely and go back to the drawing board.

While the rapid prototyping process is an excellent way to develop a product, it does have weaknesses.

• It’s not as useful for complex products. Rapid prototyping may not be the best method for testing if the prototypes are not close enough in appearance and functionality to the final product. For example, it’s difficult to make a functional prototype if you have a physical product with many moving parts (like a new type of engine) or if your website or video game relies on a unique, difficult-to-code custom mechanic.
• It costs more upfront. The more prototypes you test before manufacturing your product, the more expensive the product development process will be. Thorough prototyping will likely save you money in the long run, but it will require more capital—especially if you’re using new rapid prototyping processes that are still relatively costly.
• It limits the materials at your disposal. While rapid prototyping can be great for testing a proof of concept, it won’t give you a sense of the strength, color, or surface finish of the final product.

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