F O R MLA B S W H ITE PA PER:

The Ultimate Guide to

Rapid Prototyping for
Product Development

January 2018 | formlabs.com

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

What is Rapid Prototyping? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Why Rapid Prototyping? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Applications of Rapid Prototyping . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Rapid Prototyping Tools: FDM vs. SLA vs. SLS . . . . . . . . . . . . . . . . . . . 9

Learn More About 3D Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 2
Introduction
Rapid prototyping helps companies turn ideas into realistic proofs of concept, advances these
concepts to high-fidelity prototypes that look and work like final products, and guides products
through a series of validation stages toward mass production. With rapid prototyping, designers
and engineers can create prototypes directly from CAD data faster than ever before, and
execute quick and frequent revisions of their designs based on real-world testing and feedback.

In this white paper, you’ll learn how rapid prototyping fits into the product design process, its
applications, and what rapid prototyping tools are available to today’s product design teams.

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What is Rapid Prototyping?
Rapid prototyping is the group of techniques used to quickly fabricate a scale model of
a physical part or assembly using three-dimensional computer-aided design (CAD) data.
Because these parts or assemblies are usually constructed using additive techniques as
opposed to traditional subtractive methods, the phrase has become synonymous with
additive manufacturing and 3D printing.
Additive manufacturing is a natural match for prototyping. It provides almost unlimited form
freedom, doesn’t require tooling, and can produce parts with properties closely matching
various materials made with traditional manufacturing methods. 3D printing technologies have
been around since the 1980s, but their high cost and complexity mostly limited use to large
corporations, or forced smaller companies to outsource production to specialized services,
waiting weeks between iterations.
The advent of desktop and benchtop 3D printing has changed this status quo and inspired a
groundswell of adoption that shows no sign of stopping. With in-house 3D printing, engineers
and designers can quickly iterate between digital designs and physical prototypes. It is now
possible to create prototypes within a day and carry out quick iterations of design, size, shape,
or assembly based on results of real-life testing and analysis. Ultimately, rapid prototyping
helps companies get better products to market faster than their competition.

Using 3D printing, designers can rapidly iterate between digital designs

and physical prototypes, and get to production faster.

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Why Rapid Prototyping?
REALIZE AND EXPLORE CONCEPTS FASTER
Rapid prototyping elevates initial ideas to low-risk concept explorations that look like real products
in no time. It allows designers to go beyond virtual visualization, making it easier to understand the
look and feel of the design, and compare concepts side by side.

COMMUNICATE IDEAS EFFECTIVELY

Physical models empower designers to share their concepts with colleagues, clients, and
collaborators to convey ideas in ways not possible by merely visualizing designs on screen. Rapid
prototyping facilitates the clear, actionable feedback that is essential for creators to refine and
improve their designs.

DESIGN ITERATIVELY AND INSTANTLY INCORPORATE CHANGES

Design is always an iterative process requiring multiple rounds of testing, evaluation, and
refinement before getting to a final product. Rapid prototyping with 3D printing provides the
flexibility to create more realistic prototypes faster and implement changes instantly, elevating this
crucial trial and error process.

Consecutive iterations of Sutrue, an automated surgical suturing device prototyped on Formlabs SLA printers.

A good model is a 24-hour design cycle: design during work, 3D print parts overnight, clean and
test the next day, tweak the design, then repeat.

SAVE COST AND TIME

With 3D printing, there’s no need for costly tooling and setup; the same equipment can be used
to produce different geometries. In-house prototyping eliminates the high costs and lead time
associated with outsourcing.

TEST THOROUGHLY AND MINIMIZE DESIGN FLAWS

In product design and manufacturing, finding and fixing design flaws early can help companies
avoid costly design revisions and tooling changes down the road.
Rapid prototyping allows engineers to thoroughly test prototypes that look and perform like final
products, reducing the risks of usability and manufacturability issues before moving into production.

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Applications of Rapid Prototyping
Thanks to a variety of available technologies and materials, rapid prototyping with 3D printing
supports designers and engineers throughout product development, from initial concept models to
engineering, validation, and production.

CONCEPT MODELS
Concept models or proof-of-concept (POC) prototypes help product designers validate ideas
and assumptions and test a product’s viability. Physical concept models can demonstrate
an idea to stakeholders, create discussion, and drive acceptance or rejection using low-risk
concept explorations.
The key to successful concept modeling is speed; designers need to generate a wealth of ideas,
before building and evaluating physical models. At this stage, usability and quality are of less
importance and teams rely on off-the-shelf parts as much as possible.
3D printers are ideal tools to support concept modeling. They provide unmatched turnaround time
to convert a computer file into a physical prototype, allowing designers to test more concepts,
faster. In contrast with the majority of workshop and manufacturing tools, desktop 3D printers are
office-friendly, sparing the need for a dedicated space.

Designers at Swiss design and consultancy studio Panter&Tourron

used SLA 3D printing to get from concept to showcase in two weeks.

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Diving camera manufacturer Paralenz used
3D printing to create realistic prototypes that
endured testing 200+ meters below sea level.

FUNCTIONAL PROTOTYPES
As the product moves into the subsequent stages, details become increasingly important.
3D printing allows engineers to create high-fidelity prototypes that accurately represent the
final product. This makes it easier to verify the design, fit, function, and manufacturability
before investing in expensive tooling and moving into production, when the time and cost
to make change becomes increasingly prohibitive.
Advanced 3D printing materials can closely match the look, feel, and material characteristics
of parts produced with traditional manufacturing processes such as injection molding. Various
materials can simulate parts with fine details and textures, smooth and low-friction surfaces, rigid
and robust housings, or soft-touch and clear components. 3D printed parts can be finished with
secondary processes like sanding, polishing, painting, or electroplating to replicate any visual
attribute of a final part, as well as machined to create assemblies from multiple parts and materials.
Engineering prototypes require extensive functional testing to see how a part or assembly will
function when subjected to stresses and conditions of in-field use. 3D printing offers engineering
plastics for high-performance prototypes that can withstand thermal, chemical, and mechanical
stress. The technology also provides an efficient solution for creating custom test fixtures to
simplify functional testing and certification by gathering consistent data.

Engineers at Wohlers built a looks-like, works-like prototype of a moisture

meter from multiple materials with rigid housing and soft-touch buttons.
Medical device design company Coalesce 3D printed jigs in an automated
uses custom jigs for in-house testing. production line at Pankl Racing Systems.

PRE-PRODUCTION AND MANUFACTURING

Having a great prototype is only half the battle; a design has to be repeatedly and economically
manufacturable to become a successful final product. Design for manufacturability (DFM) balances
the aesthetics and functionality of the design while maintaining the requirements of the end
product. DFM facilitates the manufacturing process to reduce the manufacturing costs and keep
the cost per part below the required level.
Rapid prototyping allows engineers to create small-batch runs, one-off custom solutions, and sub-
assemblies for engineering and design validation (EVT and DVT) builds to test manufacturability.
3D printing makes it easier to test tolerances with the actual manufacturing process in mind,
and to conduct comprehensive in-house and field testing before moving into mass production.
3D printed parts also support production, with prototyping tools, molds, jigs, and fixtures for the
production line.
With 3D printing, design doesn’t have to end when production begins. Rapid prototyping tools
allow designers and engineers to continuously improve products, and respond quickly and
effectively to issues on the line with jigs and fixtures that enhance assembly or QA processes.

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Rapid Prototyping Tools: FDM vs. SLA vs. SLS
Over the last few years, high-resolution 3D printers have become more affordable, easier to use,
and more reliable. As a result, the technology is now accessible to more businesses, but choosing
between the various competing 3D printing solutions can be difficult.
Which technology is suitable for your particular application? What materials are available? What
equipment and training do you need to get started? How about costs and return on investment?
Now, we’ll take a closer look at the three most established technologies for 3D printing plastics
today: fused deposition modeling (FDM), stereolithography (SLA), and selective laser sintering (SLS)

FUSED DEPOSITION MODELING (FDM)

Fused Deposition Modeling is the most widely used form of 3D printing at the consumer level,
fueled by the emergence of hobbyist 3D printers. FDM 3D printers build parts by melting and
extruding thermoplastic filament, which a print nozzle deposits layer by layer in the build area.
FDM works with a range of standard thermoplastics, such as ABS, PLA, and their various blends.
The technique is well-suited for basic proof-of-concept models, as well as quick and low-cost
prototyping of simple parts, such as parts that might typically be machined.
FDM has the lowest resolution and accuracy when compared to SLA or SLS and is not the best
option for printing complex designs or parts with intricate features. Higher-quality finishes may
be obtained through chemical and mechanical polishing processes. Industrial FDM 3D printers
use soluble supports to mitigate some of these issues and offer a wider range of engineering
thermoplastics, but they also come at a steep price.

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 STEREOLITHOGRAPHY (SLA)
Stereolithography was the world’s first 3D printing
technology, invented in the early 1970s, and is still one
of the most popular technologies for professionals.
SLA uses a laser to cure liquid resin into hardened plastic
in a process called photopolymerization.
SLA parts have the highest resolution and accuracy,
the clearest details, and the smoothest surface finish
of all plastic 3D printing technologies, but the main
benefit of SLA lies in its versatility. Material manufacturers
have created innovative SLA resin formulations with
a wide range of optical, mechanical, and thermal
properties to match those of standard, engineering,
and industrial thermoplastics.
SLA is a great option for highly detailed prototypes
requiring tight tolerances and smooth surfaces, such
as molds, patterns, and functional parts. SLA is widely
used in a range of industries from engineering and
product design to manufacturing, dentistry, jewelry,
model making, and education.
Request a free sample part and see the SLA
quality firsthand.
SELECTIVE LASER SINTERING (SLS)
Selective laser sintering is the most common additive
manufacturing technology for industrial applications.
SLS 3D printers use a high-powered laser to fuse small
particles of polymer powder. The unfused powder
supports the part during printing and eliminates the
need for dedicated support structures. This makes SLS
ideal for complex geometries, including interior features,
undercuts, thin walls, and negative features. Parts
produced with SLS printing have excellent mechanical
characteristics, with strength resembling that of injection-
molded parts.
The most common material for selective laser sintering
is nylon, a popular engineering thermoplastic with
excellent mechanical properties. Nylon is lightweight,
strong, and flexible, as
well as stable against impact, chemicals, heat, UV light,
water, and dirt.
The combination of low cost per part, high productivity,
and established materials make SLS a popular choice
among engineers for functional prototyping, and a cost-
effective alternative to injection molding for limited-run or
bridge manufacturing.

FDM parts tend to have visible layer lines
and might show inaccuracies around
complex features. This example was printed
on a Stratasys uPrint industrial FDM 3D
printer with soluble supports (machine
starting at $15,900).
SLA parts have sharp edges, a smooth
surface finish, and minimal visible layer
lines. This example part was printed on a
Formlabs Form 2 desktop SLA 3D printer
(starting at $3,499).
SLS parts have a slightly rough surface
finish, but almost no visible layer lines.
This example part was printed on a
Formlabs Fuse 1 benchtop SLS 3D printer
(starting at $9,999).
COMPARE FDM, SLA, AND SLS TECHNOLOGIES
Each 3D printing technology has its own strengths, weaknesses, and requirements, and is suitable for different
applications and businesses. The following table summarizes some key characteristics and considerations.

Fused Deposition Modeling Stereolithography Selective Laser Sintering

FDM SLA SLS

Resolution

Accuracy

Surface Finish

Throughput

Complex Designs

Ease of Use

Pros Fast Great value Strong functional parts

Low-cost consumer machines High accuracy Design freedom
and matreials Smooth surface finish No need for support structures
Range of functional applications

Cons Low accuracy Average build volume Rough surface finish

Low details Sensitive to long exposure Limited material options
Limited design compatibility to UV light

Applications Low-cost rapid prototyping Functional prototyping Functional prototyping

Basic proof-of-concept models Dental applications Short-run, bridge, or custom
manufacturing
Jewelry prototyping and casting
Modelmaking

Print Volume Up to ~200 x 200 x 300 mm Up to 145 x 145 x 175 mm (desktop Up to 165 x 165 x 320 mm
(desktop 3D printers) 3D printers) (benchtop 3D printers)

Materials Standard thermoplastics, such Varieties of resin (thermosetting Engineering thermoplastics.

as ABS, PLA, and their various plastics). Standard, engineering Nylon 11, Nylon 12, and their
blends. (ABS-like, PP-like, flexible, heat- composites.
resistant), castable, dental, and
medical (biocompatible).

Training Minor training on build setup, Plug and play. Minor training Moderate training on build setup,
machine operation, and on build setup, maintenance, maintenance, machine operation,
finishing; moderate training on machine operation, and finishing. and finishing.
maintenance.

Facility Air-conditioned environment or Desktop machines are suitable for Workshop environment with
Requirements preferably custom ventilation for an office environment. moderate space requirements
desktop machines. for benchtop systems.

Ancillary Support removal system for Post-curing station, washing Post-processing station for part
Equipment machines with soluble supports station (optionally automated), cleaning and material recovery.
(optionally automated), finishing finishing tools.
tools.

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COSTS AND RETURN ON INVESTMENT
Ultimately, you should choose the technology that makes the most sense for your business.
Prices have dropped significantly in recent years, and today, all three technologies are available in
compact, affordable systems.

Calculating costs does not end with upfront equipment costs. Material and labor costs have a
significant influence on cost per part, depending on the application and your production needs.

Here’s a detailed breakdown by technology:

Fused Deposition Modeling Stereolithography Selective Laser Sintering

FDM SLA SLS

Equipment Costs Mid-range desktop printers
start at $2,000, and industrial
systems are available from
$15,000.
Professional desktop Benchtop systems start
printers start at $3,500, at $10,000, and industrial
and large-scale industrial printers are available from
machines are available $100,000.
from $80,000.

Material Costs $50-$150/kg for most
standard and engineering
filaments, and $100-200/kg
for support materials.
$149-$200/L for $100/kg for nylon. SLS
most standard and requires no support
engineering resins. structures, and unfused
powder can be reused,
which lowers material
costs.

Labor Needs Manual support removal
(can be mostly automated
for industrial systems with
soluble supports). Lengthy
post-processing is required
for a high-quality finish.
Washing and post-curing Simple cleaning to remove
(both can be mostly excess powder.
automated).
Simple post-processing to
remove support marks.

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 Form 2 Fuse 1
Intuitive, reliable stereolithography The industrial power of selective
for the desktop laser sintering for the benchtop

Learn More About 3D Printing

Contact Formlabs to learn how you can get started with 3D printing and see the
print quality firsthand by requesting your free 3D printed sample part.

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