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Last week I asked you to list some good visual prototyping questions and received some insightful responses. I’d like to expand a bit upon that thread and figure out what the common research questions are for four prototyping stages:

Proof of principle prototypes: To test technical aspects of the product before investing in a more functional version​

  • Mechanical testing: Does this part meet the minimum criteria for property x (e.g. tensile strength, elongation at break)?
  • Mechanical testing: Is this material suitable for its intended application?
  • Is it feasible to integrate this technology into the product architecture?

Form & fit prototypes: To provide feedback regarding the look, fit and overall feel of the product.

  • What is the optimal size for this part?
  • How will this part fit into the overall product architecture?
  • How can we improve the ergonomics of this part?
  • How can we improve the aerodynamics for this part?

Visual prototypes: Whereas a form prototype is still a rough version of the final product, a visual prototype resembles the actual product in look, feel, material and dimensions.

  • How’s this design perceived by stakeholders (customers, managers, clients, departments)?
  • How’s this design perceived by stakeholders compared to competitive offerings?
  • How can we further improve product aesthetics / colors?
  • How can we decrease production cost without affecting visual quality?
    • Can we leave out certain parts?
    • Can we use cheaper materials?

Functional prototypes: A functional prototype captures both function and appearance of the intended design. All visual prototyping questions AND:

  • Do all components in the assembly function accordingly?
    • ​Are the mechanical clearances and tolerances in accordance with design specifications?
  • Can we adjust the shape of certain components to improve function?
  • Are the components of the design positioned logically / intuitively?
  • Which components in the assembly are the weakest link?
  • How can we further decrease production cost without affecting function?
    • Can we leave out certain parts?
    • Can we use cheaper materials?

For the 3D Hubs knowledge base (big content project I’m working on) I’d like to write an article that lists common research questions per prototyping stage and illustrates their relevance through practical examples. The goal is to show how 3D printing is used for prototyping within our community and to give readers new ideas on how to apply 3D printing in their prototyping cycles.

You can help me out by:

  • Letting me know what research questions are missing or can be improved
  • Supplying me with example prototypes you printed to answer one or more of the questions listed. You can either use the comments section or email them to stijn@3dhubs.com. I’ll integrate the best suggestions into the article.

With your help, I’d like to write a community sourced article that shows “Why 3D Printing is the ultimate prototyping tool”.

Thanks in advance

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In terms of the statement of the article “Why 3D Printing is the ultimate prototyping tool”, in my opinion this is just one of many prototyping techniques, and the ultimate tool is dependant on any given project.

For example, we often CNC machine solid models rather than 3D print, as it can be faster, cheaper, more robust and better to finish.

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How is there only one response to this? Here is the outside to a 3’ long part printed in “draft mode” which is a rapid prototype method and one of our specialties. It is about 40 hours of print time, 6 pieces and sub $200. The customer designed this as a chassis for a mechanical assembly and is looking to answer questions regarding “rough fit and size” Are the components of the design positioned logically / intuitively? Will the internal components fit and have proper clearance? Are the walls thick enough for final casting? There has to be other hubs with at least one example of a prototype print?

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I also have a middle school student who is building a rocket. She sent some photos of the actual testing of a rocket engine in her ABS engine mount. Mechanical testing: Is this material suitable for its intended application?