Different methods, what you can expect and what the process will accomplish.

1. An original type, form, or instance that serves as a model on which later stages are based or judged.
2. An early, typical example.
3. Biology. A primitive or ancestral form or species. The main purpose of prototyping a product is to find out if it will work in the application it is designed for.

A major step in product development. The information gained from the prototype part is used to refine the product to make it more functional, more useful, more user friendly or just more appealing to the end user. This may take many forms from material selection, surface finishes, geometry changes or changing the design concept. The selection of the prototyping method is dictated by what needs to be learned from the prototype. It is unlikely the first edition of prototype parts will be satisfactory for marketing purposes. If that were not the case, there would be no sense in going to the expense of prototyping. Modifications to the design or materials should be expected and used to learn from. The number of times a product will have to be modified is difficult to predict, as are the associated cost.

Prototype Parts( Machined from extruded shapes ) The least expensive method of prototyping. Limited to available stock of the intended material. Machining puts excessive stress in the plastic, although some material can be annealed to relieve stress. This method usually allows testing for physical, thermal and electrical properties. We can resource the appropriate material and shape for this method for you, as well as do the machining.

Prototype Parts( Rapid Prototyping) Several methods are available today all are accomplished from 3D geometry generated by design software on computers (Pro-E). Sterolithography is one of the more popular methods. The equipment is driven by a computer file that traces the geometry of the part with a laser in a vat of photosensitive polymers. This type of prototype part is only good for fit form and function. The materials used in sterolithography are thermoset, therefore no information about physical, thermal or electrical properties of the prototype part can be learned. Typical lead times are a few days and cost is minimal. Changes in the design cost are moderate and not as expensive as with parts from a prototype mold.

Prototype Parts( Molded in a prototype mold)  The most expensive and also the best method of prototyping. Most molds are made with aluminum and are constructed in the least expensive method. These molds are not intended for production although many hundreds of parts may be produced. The advantage here is material selected for production parts can be used in the prototype mold. The prototype mold very closely resembles the production mold and parts can be fully tested for physical, thermal or electrical properties. Changes to the design can be expensive, in that the mold has to be modified.
There are several other methods of prototyping with various advantages as well as limitations. Today's technology in prototyping is changing at a very fast rate. We use the above methods on an ongoing basis in the product development work we do with our customers. If you would like information on AIM prototyping or any of the newer methods just drop us an E-mail.

The above information is of a general nature and is intended for a basic understanding of one of the processes we use in the product development stage to help bring our customers products to market. There are exceptions to every process or method depending on the individual application.