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Functional Rapid Prototyping Technology

Dwight Mitchell • 30 June 2022

3D Printing as a Functional Rapid

Prototyping Technology using metal,

plastic and resin materials. What are

the software requirements for

creating a manufacturable part

Any engineer will tell you that reducing time to market for new products is paramount to business success. The sooner you can get your product to market, the faster you can begin selling it and recouping your development costs. It’s no wonder, then, that engineers are always on the lookout for ways to streamline their design processes. That’s where rapid prototyping comes in. 3D printing as a functional rapid prototyping technology uses different materials and processes to create a model of an object that has a limited set of functions. Here we will dive into what each of these terms means and how they work together to help engineers create prototypes faster than ever before

What is Functional Rapid Prototyping?

Functional Rapid Prototyping, or FRP, is a technique used to create a model of an object that has a limited set of functions. In other words, a prototype created using this process is designed to look and feel like the final product, but doesn’t have the same functionality. Functional prototypes are useful for testing the design of a product. They allow engineers to iron out potential issues with fit, form and function, before they spend the time and money required to produce a fully-functioning batch of the product. Functional prototypes can be created in many different ways. They can be made from a wide variety of materials, including metals, plastics, and ceramics. They can also be manufactured using a number of different production techniques: CNC machining, injection molding, 3D printing and more. In fact, 3D printing is increasingly being used as a functional rapid prototyping technology thanks to its relatively low cost, short production times and ability to create prototypes in a wide range of materials.

Why Is Functional Rapid Prototyping Important?

Achieving a smooth and timely transition from design to production is critical for any product team. With functional rapid prototyping, engineers can test their designs earlier and identify potential issues much sooner. This means they can make changes to their designs in a shorter timeframe and avoid potential problems that would otherwise delay production. Functional rapid prototyping is especially important for engineers in high-risk, high-cost sectors, such as the aerospace and automotive industries. Here, creating a fully functional prototype can be extremely costly, and may even be impossible for technical reasons. Functional rapid prototyping allows engineers to create a model that mimics the look and feel of the finished product, without the need for expensive materials that can only be used once. This means they can test their designs earlier, identify potential issues and make changes early on, saving time and money in the long run.

How Does 3D Printing Function as a Rapid Prototyping Tool?

There are many different ways to create a functional rapid prototype. One of the most popular is 3D printing. Typically, engineers use 3D printing to create a model of the object they are trying to produce in one of two ways: They can manufacture a part directly from CAD software, or they can use a 3D scan of an existing product. Engineers can also use 3D printing to create a mould or tooling that can be used to make a part made of a different material, such as metal, plastic or resin. 3D printing creates a prototype in one of two ways: by extrusion or by additive manufacturing. Both of these processes are used to create a part, one layer at a time, from a digital design. The only difference is in the way the model is created.

3D Printing with Metal Using additive manufacturing techniques.

With this approach, an engineer will use CAD software to design a part made from a variety of different materials, such as metal, plastic, carbon fibre and more. This design will be saved as a file that can be sent to a 3D printer made from the same materials. Using this machine, the engineer can create a model of the original design. This model is produced by adding layers of material until the desired shape has been formed. Because additive manufacturing techniques use software to control the printing process, an engineer can also use this process to create a prototype that includes built-in engineering functions, such as moving parts. This technique is used to create a functional prototype of an object made completely or partially from metal. However, an engineer must be careful to select a printing material that is suited to the function of the design. For example, a 3D printer made from a metal alloy that has been specially treated to be flexible can be used to create a functional prototype of a shoe sole.

3D Printing with Plastic Using an extrusion process.

This is a very popular method of 3D printing a functional prototype. Engineers can create a design in CAD software made from a variety of different materials, such as plastic, nylon, polyurethane and more. Using this design, the engineer can create a file that can be sent to a 3D printer made from the same materials. This machine uses an extrusion process to create a model of the original design. The machine heats up the material, flows it through a nozzle, and layers it onto a platform. While this process is occurring, an engineer can adjust the temperature, pressure and feeding speed to modify the model’s design. This technique is used to create a functional prototype of an object made completely or partially from plastic. However, an engineer must be careful to select a printing material that is suited to the function of the design. For example, a 3D printer made from a flexible plastic can be used to create a functional prototype of a shoe sole.

3D Printing with Resin Using a resin process.

This method of 3D printing a functional prototype is often used to create models of objects made completely or partially from plastic. Engineers use CAD software to design a part made from one of many different types of plastic resin. This design is saved as a file that can be sent to a 3D printer made from the same materials. The machine uses a resin process to create a model of the original design. During this process, the engineer can adjust the temperature and flow rate of the resin to modify the model’s design. This technique is used to create a functional prototype of an object made completely or partially from plastic. However, an engineer must be careful to select a printing material that is suited to the function of the design. For example, a 3D printer made from a flexible plastic resin can be used to create a functional prototype of a shoe sole.

Key takeaways

Regardless of the technique used, engineers can create a functional prototype using 3D printing. This model can be designed to look and feel like the finished product, but without the same functionality. Functional prototypes created using 3D printing are particularly useful for testing the design of a product. They allow engineers to iron out potential issues with fit, form and function, before they spend the time and money required to produce a fully-functioning batch of the product.