Prototypes & functional models

There are different kinds of prototypes, each serving different purposes. For example, the complexity of the technical function to be tested plays a role, as does the scope of the required prototype series.

Design prototype

The design prototype is used for practical verification of aesthetic and ergonomic aspects of industrial design or even product design. From a technical point of view, it is usually less functional.

Concept prototype

The concept prototype is used to test partial technical solutions and partial functions.

Geometric prototype

A geometric prototype helps verify assembly and handling functions by providing a dimensionally accurate representation of the system. At the same time, the geometric prototype may have functional limitations due to prototype material and process.

Functional prototype

The functional prototype is a prototype that represents most or even all of the functions of the actual technical system. Due to the systematically carried out selection of material and manufacturing process, it partly enables a pre-qualification.

• Additive Manufacturing / 3D Printing
  
  • Selective Laser Sintering SLS
  • Stereolithography (SLA)
  • PolyJet/MultiJet technology
• Vacuum casting
• 3D CNC milling

The so-called rapid tooling processes are used to produce simple shaping tools for prototype production. Shaping tools for prototypes are used, for example, when the scope of the prototype series is large or when a high level of detail is required for the later technical system. With molding tools, components can be produced in near-series component quality within a few days or individual weeks.

Rapid tooling for small to medium prototype series

Injection molds made of high-strength aluminum allow for small to medium prototype quantities of around 5,000 units. Depending on the degree of complexity, undercuts, surfaces and a component quality similar to that of the series production process can be achieved.

Rapid tooling for medium to large prototype series

Single-cavity prototype molds made of steel have a higher stability compared to aluminum molds. They enable medium to high volumes of prototype components to be produced which correspond to those from a series injection molding process. These steel prototype molds can subsequently be partially integrated into multi-cavity injection molds for the series production process, making prototype production more cost-efficient.

Frequently used rapid tooling processes

• Aluminum molds
• 3D Printing Tools
• Resin molds