Prototype construction

Prototyping refers to the three-dimensional production of functional prototypes (test models) of a planned product. Depending on the purpose and properties that are to be tested with the help of such a model during development, a prototype can correspond to the end product either visually or technically. A prototype is therefore used to check the appearance or functionality of a workpiece before series production begins. In this way, potential sources of error are detected and eliminated. Prototyping is an efficient way of extensively testing and optimizing new components.

Functional model components

Prototype construction represents the rapid production of functional sample components and test models. Prototype construction is particularly recommended during development, when creating new types of workpieces for any industry, in order to perfect and realize an idea quickly and cost-effectively. The aim is to work effectively, without tools and without manual detours, exclusively using CAD programs. The defined and appropriately adapted data is then implemented using laser sintering or laser melting processes.

Prototypes serve as preparation for series production and can correspond to the planned end product both visually and technically. Many sectors and branches of industry are increasingly relying on individualized products and a high number of variants. Small series and prototype construction are the means of choice here in order to take as little risk as possible with the investment.

If you only need a single component that is not to go into series production, prototyping is also a good option for manufacturing the optimized end product. Prototyping produces fully functional and usable workpieces.

Which processes are used in prototype construction?

Technologies used in prototyping are additive manufacturing (AM) processes such as laser melting (SLM), laser sintering (SLS) and others. The 3D printing processes currently available, such as laser sintering or laser melting, are ideal for building prototypes. Components can be produced quickly from digital 3D CAD data under computer control. Whether a sintering or melting process is used depends on the material of the prototype – SLM is used for metals and SLS for plastics.

The advantages of prototyping

Sources of error in the end product are minimized as far as possible in the development stage before series production has even begun. This not only reduces the risk of malfunctions in the finished end product, but also significantly reduces the investment risk. These advantages are convincing across all industries. This is why rapid prototyping is now used in the design and draft phase in almost all industries. Potential sources of error are changed in the CAD program and new test models are produced until everything fits. Once the idea has been successfully implemented, rapid tooling and rapid manufacturing can be used to produce components and tool parts in small series.

The advantages of prototyping with 3D printing at a glance:

  • Time efficiency
  • Minimization of investment risks
  • Optimization of the component during development

Prototype construction at FKM

At FKM, we carry out rapid prototyping using laser sintering and laser melting. We have a wide range of metals and plastics available that can withstand different mechanical, thermal or chemical stresses. This allows you to select the optimum material for your project so that the prototype already has properties that are as close to series production as possible.