Today’s product designers have a variety of prototyping processes available to them. Some still rely on traditional manufacturing methods, while others use sophisticated technologies that have been improved upon over the years. The objective is to quickly determine which process or technology is best suited for your unique application.
Traditional rapid prototyping processes that use thermoplastics or polycarbonates, i.e. Stereolithography (SLA), Fused Deposition Modeling (FDM) or Selective Laser Sintering (SLS) are great for testing form, but many times these processes are no substitute for testing with real rubber compounds that will actually be used in production.
In the early stages of the design process concept models are very useful. As the design progresses, a prototype that encompasses the size, finish, color, shape, strength, durability and material characteristics of the intended final product becomes increasingly important. Therefore, using the right material and prototyping process becomes critical.
If your prototype can accurately represent the attributes of the end-product, it is by definition functional. These requirements often include material properties (e.g. flame resistance), dimensional accuracy for compatibility with mating parts and aesthetic surface finishes for appearance.
If your prototype design can be reproduced in a manner that supports the requirements of the end-product, it is by definition manufacturable. These requirements include the ability to maintain functionality, keep within the forecasted cost structure, and support the production schedule. No matter how great your design is though, it must still be manufactured for a profit. Make sure your prototyping process takes this into account.
Finally, even though your prototype design may be functional and manufacturable, it doesn’t mean anyone will want to use it. Prototypes are the only way to really verify the viability of the design. If your design can pass the challenges associated with market trials (e.g. tradeshow displays, usability testing) and regulatory testing (e.g. FDA testing of medical devices), you’re well on your way to a successful product launch.
Companies like Vicone, who specialize in high performance rubber materials, can provide product designers the fastest, easiest and most cost-effective method of obtaining low volumes of molded or extruded rubber parts. By streamlining the “CAD model-to-prototype” process you will not only reduce your lead times, but be better able to validate your design and ensure proper fit, form and function in all testing environments.