Guide to Rapid Tooling - Formlabs

Injection molding is one of the most popular manufacturing processes for thermoplastic, silicone, or rubber parts. Due to the excessively high costs of traditional metal tooling, it is also the process that can benefit most from rapid tooling. 

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With affordable desktop resin 3D printers and temperature-resistant 3D printing materials, it is possible to create 3D printed injection molds in-house to produce functional prototypes and small, functional parts in production plastics. 

For low-volume production (approximately 10- parts), 3D printed injection molds save time and money compared to expensive metal molds. They also enable a more agile manufacturing and product development approach, allowing engineers and designers to create functional prototypes or low-volume end-use parts to validate material choice and continue to iterate on their designs with low lead times and cost before investing in hard tooling.

Stereolithography (SLA) 3D printing provides a cost-effective alternative to machining aluminum or steel molds. SLA 3D printed parts are fully solid and isotropic, and materials are available with a heat deflection temperature of up to 238°C @ 0.45 MPa, meaning that they can withstand the heat and pressure of the injection molding process.

Shenzhen-based contract manufacturer Multiplus uses 3D printed injection molds with the highly glass-filled and heat resistant Rigid 10K Resin on Formlabs resin 3D printers, shortening lead times for small batches of around 100 injection molded parts, from four weeks to only three days.

As an alternative for mid-volume production of about 500 to 10,000 parts, machining molds out of aluminum can also reduce the fixed costs associated with manufacturing molds. Machining aluminum is five to ten times faster than steel and causes less wear on the tooling, which means shorter lead times and lower costs. Aluminum also conducts heat faster than steel, resulting in less need for cooling channels and allowing manufacturers to simplify mold designs while maintaining short cycle times.

Many businesses turn to SLA 3D printing to create molds for thermoforming processes, because it offers a fast turnaround time at a low price point, especially for shorter runs, custom parts, and prototype designs. 3D printing also offers unmatched design freedom to create complex and intricate molds. Use the Form 4 desktop SLA printer to produce smaller molds, and the Form 4L large format 3D printer for mold sizes up to 35.3 x 19.6 x 35 cm (13.9 x 7.7 x 13.8 in).

Product development firm Glassboard leverages the fast print speed of Fast Model Resin to quickly produce molds and thermoform polycarbonate prototypes such as helmet shells or packaging. They can achieve complicated mold shapes that would be difficult to manufacture traditionally, including small features and holes for an even better vacuum distribution across the surface.

Cosmetics manufacturer Lush used to craft the master molds for their popular products by hand. But recently, they turned to 3D printing to create vacuum forming molds for detailed and textured designs, which allows them to take ideas from concept to reality in under 24 hours, and test more than a thousand design ideas each year.

High-performance composite materials such as carbon fiber can also be hand laminated on 3D printed molds. SLA 3D printers offer a smooth surface finish that is essential for layup molds.

The Formula Student team of TU Berlin hand laminates carbon fiber parts on 3D printed molds for racing cars. Printed with Tough Resin, the mold is not only strong and supportive during the layup but also sufficiently flexible to separate the part from the mold after curing, unlocking design possibilities.

Google’s ATAP team used 3D printed stand-ins, or surrogate parts instead of overmolded electronic sub-assemblies for the initial tool tuning at the factory.

Designers at the Google Advanced Technology and Projects (ATAP) lab were able to cut costs by more than $100,000 and shorten their testing cycle from three weeks to just three days using a combination of 3D printing and insert molding. Google ATAP’s team found that by 3D printing test parts, they could save time and money over using expensive electronic parts that had to be shipped in from a supplier.

Dame Products, a Brooklyn-based startup, designs products for the health and wellness industry. They employ silicone insert molding to encapsulate internal hardware for customer beta prototypes. The Dame Products product line incorporates complex ergonomic geometries fully encapsulated in a layer of skin-safe silicone in vibrant colors.

Engineers prototype dozens of insert and overmolded devices in a single day by rotating through three or four SLA 3D printed molds. While the silicone rubber of one prototype is curing, the next can be demolded and prepared for the next fill; the finishing and cleaning of demolded prototypes happens in parallel. When prototype hardware is returned to the company, the beta device is bleached, the thin silicone layer removed, and the internal hardware is reused in a new beta prototype.

3D printed rapid tooling for compression molding can be leveraged for the production of thermoplastic, silicone, rubber, and composite parts. For prototyping small or medium-size parts, 3D printing may be the cheapest and fastest method for creating molds. Multiple iterations can be made quickly with CAD software, reprinted, and then tested. 3D printing is most commonly used for compression molds intended for heatless applications.

Product developers at kitchen appliance manufacturer OXO use 3D printing for prototyping rubbery components such as gaskets by compression molding two-part silicone using 3D printed molds.

Engineers, designers, jewelers, and hobbyists can capitalize on the speed and flexibility of 3D printing by combining metal casting processes like indirect investment casting, direct investment casting, pewter casting, and sand casting with 3D printed patterns or casting metal into 3D printed molds. Casted metal parts using 3D printed rapid tooling can be produced in a fraction of the time invested in traditional casting and at a significantly lower cost than metal 3D printing. 

Stereolithography 3D printers offer high precision and a broad material library that is well-suited for casting workflows and can produce metal parts at a lower cost, with greater design freedom, and in less time than traditional methods. 

Traditionally, patterns for direct investment casting are carved by hand or machined if the part is a one-off or expected to be only a handful of units. With 3D printing, however, jewelers can directly 3D print the patterns, removing the design and time constraints common in other processes. 

Similar to investment casting, 3D printing can be used to create patterns for sand casting. In comparison to traditional materials like ​​wood, 3D printing allows manufacturers to create complex shapes and go straight from digital design to casting. 

With 3D printing, manufacturers can also directly 3D print the mold for their pattern using materials like High Temp Resin or Rigid 10K Resin, resins with high-temperature resistance. The same method can also be used to create molds for direct pewter casting.

Beyond metals, casting is also a popular method for producing silicone and plastic parts for medical devices, audiology, food-safe applications, and more.

Medical device company Cosm manufactures patient-specific pessaries for patients with pelvic floor disorders. They 3D print molds on an SLA 3D printer and inject biocompatible, medical-grade silicone into it to create the part. Rapid tooling with 3D printing allows them to create custom parts without the high costs of traditional tooling.

3D printed rapid tooling presents some interesting properties for sheet metal forming as well. Characterized by high precision and a smooth surface finish, SLA 3D printers can fabricate tools with excellent registration features for better repeatability. Thanks to a broad material library with various mechanical properties, choosing a resin tailored to the specific use case can optimize the result of the forming. SLA resins are isotropic and fairly stable under load compared to other 3D printing materials. Plastic tooling can also eliminate a polishing step, as plastic dies do not mark the sheet as metal. 

3D printing is the fastest and most affordable way to produce rapid tooling for a variety of applications. As we saw in the previous examples, both direct and indirect rapid tooling leverages 3D printing in different ways to develop functional tools, such as molds, patterns, and dies for a variety of traditional manufacturing processes.

From the different 3D printing processes, SLA 3D printers offer the most versatile solutions for tooling. SLA 3D printed parts are accurate, watertight, have a smooth surface finish that is ideal for molds, and can replicate small details for complex molds and patterns.

Machining is one of the most common methods for manufacturing conventional tooling and hard tooling, but it can also be leveraged for creating rapid tooling. Instead of durable metals such as steel or nickel alloys, rapid tooling is most commonly machined out of tooling board, wood, plastic, or aluminum.

Compared to 3D printed tooling, machined tooling out of soft materials can be more efficient for large-format tooling and simple shapes, but it gets increasingly labor-intensive and expensive in line with design complexity. Aluminum tooling is more durable and is generally used for low to mid-volume production, especially for injection molding.

Machining tools are more expensive, require a trained operator, and have a complex workflow for in-house production compared to 3D printers, especially for one-off parts like consecutive prototype iterations of rapid tooling. As a result, many companies outsource machining to service providers, but this comes with an often multiple weeks-long lead time and the rapid factor of rapid tooling quickly diminishes.

Rapid prototyping is changing how products are developed by enabling manufacturers to quickly turn ideas into physical prototypes through methods like 3D printing, CNC machining, and more. This approach speeds up the design process, allowing for quicker iterations and more efficient product development.

To fully benefit from rapid prototyping, companies need the right tools, equipment, and expertise. Without these, the process can become inefficient, leading to delays and increased costs. Fortunately, partnering with a specialized rapid prototyping company can bring the necessary capabilities and experience to help you achieve your production goals quickly. 

In this article, we explore the top rapid prototyping companies that are suitable partners for your production needs.  

What is Rapid Prototyping? 

Rapid prototyping is a manufacturing method that quickly produces a physical prototype of a design using a computer-aided design (CAD) model. This process typically employs additive manufacturing methods, like 3D printing, where the part is built layer by layer. However, it can also involve subtractive methods such as CNC machining, laser cutting, and casting.

The key advantage of rapid prototyping is its ability to create prototypes that closely resemble the final product. This enables manufacturers to test and refine designs before committing to mass production, allowing for tangible testing of product ideas before making significant investments.

How Does Rapid Prototyping Work? 

Rapid prototyping often begins with the creation of a CAD model using CAD software. A CAD model is a digital 2D or 3D drawing of the prototype to be created. It contains essential information such as measurements and other necessary design specifications.

The CAD model is then processed and converted into a format suitable for the rapid prototyping method you’re using, often STL or stereolithography file,  due to its simplicity, universal compatibility, and data security. 

The rapid prototyping machine is prepared or calibrated and the material, which could be plastic, metal, or resin, is set up. The CAD model is uploaded to a machine that reads the data in the CAD file and translates it to instructions for the production process. Using these instructions, the machine begins the creation of the prototype. 

After the prototype is produced, it can be sent for post-processing operations such as dying, painting, assembling, and other processes intended to improve aesthetics or functionality. 

Best Rapid Prototyping Companies

The right rapid prototyping company will deliver accurate prototypes, reduce lead times, and offer tailored solutions for each stage of your product’s development. Some of the best rapid prototyping companies you can choose from include:

1. UPTIVE Advanced Manufacturing

Location: Multiple locations across the United States and Mexico

Founded:

UPTIVE Advanced Manufacturing is a top manufacturing firm offering rapid manufacturing solutions that blend cutting-edge technology with personalized service. The company offers a range of services that include 3D printing services, traditional manufacturing, and other novel services tailored for both small and large-scale manufacturing. 

UPTIVE combines the best of traditional manufacturing methods and advanced additive manufacturing capabilities to deliver high-quality and functional prototypes. UPTIVE’s rapid prototyping services prioritize speed, customization, and precision, ensuring that each project is delivered with rapid turnaround times and tailored to your specific needs. By blending personalized service with advanced manufacturing technologies, UPTIVE guarantees high-quality results that meet immediate and long-term production goals.

The company’s rapid prototyping capabilities include solutions such as direct metal laser sintering (DMLS), selective laser sintering (SLS), fused deposition modeling (FDM), stereolithography (SLA), HP multi jet fusion (MJF), polyjet (PJP), CNC prototyping, and sheet metal prototyping. Each rapid prototyping technological capability is tailored to shorten cycle times and create better long-term manufacturing results.  

As the second-largest  HP Multi Jet Fusion service provider in the United States and an operator of 15 Markforged and 3 Stratasys printers, UPTIVE delivers precision and speed while solving critical production challenges across industries.

Capabilities: 

• Rapid prototyping
• Additive manufacturing
• CNC machining
• Sheet metal fabrication
• Injection molding and tooling
• Post-processing and finishing 

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2. Xometry 

Location: North Bethesda, Maryland

Founded:

Xometry is an AI-powered marketplace that connects customers with a diverse network of manufacturers offering on-demand manufacturing services. This marketplace supports a range of manufacturing capabilities, from plastic injection molding to die casting and laser cutting. 

Capabilities: 

• Additive manufacturing
• CNC machining
• Sheet and tube fabrication 
• Plastic part production
• Metal part production 
• Value-added solutions

3. 3ERP

Location: New York, USA

Founded:

3ERP offers rapid prototyping and low-volume production solutions to businesses that require on-demand production services. The company’s portfolio includes manufacturing solutions such as aluminum and steel tooling for plastic parts, sheet metal fabrication, and pressure die casting for metals.

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Capabilities: 

•  CNC machining
• Injection molding 
• Sheet metal fabrication 
• Custom extrusion 

4. Dblitz

Location: Houston

Founded:

Dblitz offers rapid prototyping services that involve designing, building, and testing initial prototypes. The company uses advanced algorithms, a process known as digital twins, and an integrated hybrid manufacturing approach that blends rapid prototyping and subtractive production techniques to achieve the execution of its services. Dblitz’s provides services for various industries, including automotive, construction, agriculture, and aerospace industries. 

Capabilities: 

• Rapid prototyping 
• Robotic assembly and testing

4. Dblitz

Location: Houston

Founded:

Dblitz offers rapid prototyping services that involve designing, building, and testing initial prototypes. The company uses advanced algorithms, a process known as digital twins, and an integrated hybrid manufacturing approach that blends rapid prototyping and subtractive production techniques to achieve the execution of its services. Dblitz’s provides services for various industries, including automotive, construction, agriculture, and aerospace industries. 

Capabilities: 

• Rapid prototyping 
• Robotic assembly and testing

5. ProtoXYZ

Location: New Bedford, Massachusetts 

Founded:

ProtoXYZ is a prototyping and manufacturing company whose platform is committed to creating custom parts. Their platform leverages automation and artificial intelligence to collect online orders for custom parts and generate instant quotes. ProtoXYZ offers capabilities such as CNC machining and 3D printing, as well as a catalog of production materials, including aluminum, alloy steel, and brass. 

Capabilities: 

• CNC machining
• 3D printing
• Consultation

6. Hyphen Innovations

Location: Dayton, Ohio, USA

Founded:

Hyphen Innovations is a concept-to-prototype aerospace and defense manufacturer that offers low-cost designs, testing, and part manufacturing. The company focuses on turbine engine structural integrity, vibration suppression design, and advanced manufacturing solutions for the aerospace industry. 

Hyphen Innovations creates complex structural components by combining various manufacturing processes to make prototypes, including low-cost laser powder bed fusion (LPBF), metal fused deposition modeling (FDM), metal binder processes, and laser wire-fed DED (Directed Energy Deposition). 

Capabilities: 

• Testing capabilities
• Vibration mitigation 
• Structural integrity assessment
• Metal additive manufacturing

7. Manser Edbrooke Technology

Location: Tallahassee, Florida, USA

Founded:

Manser Edbrooke Technology is a rapid prototyping company with a focus on dynamic systems, mechanics, and fluid mechanics. The company has experience in CAD design and uses a range of CAD modeling tools to create custom designs and help engineers take their products from idea to market. 

At Manser Edbrooke Technology, the flagship product is Firebird, a tabletop computer numeric control (CNC) milling machine that enables the creation of prototypes out of wood, aluminum, high-density plastics, and aluminum. 

Capabilities: 

• 3D modeling
• CNC milling
• 5-axis CNC milling
• Research and development

8. 3D Systems

Location: Rockhill, South Carolina, USA

Founded:

3D Systems offers a range of services that include hardware, software, and material solutions. The company engineers, manufactures, and sells 3D printers, 3D-printed parts, and 3D-printed materials ranging from metal to plastics, as well as application engineering services. 3D Systems provides services to various industries, including healthcare and automotive, creating functional prototypes and final parts that fit the needs of the industries. 

Capabilities: 

• Stereolithography 
• Selective laser sintering

9. Carbon 3D

Location: California, USA

Founded:

Carbon 3D is a digital manufacturing company that manufactures and develops 3D printers that use a proprietary Continuous Liquid Interface Production process. The company offers a suite of solutions encompassing software, hardware, and material solutions, facilitating both prototyping and final part production. Carbon uses its 3D printers which include Carbon M1, M2, and M3, to provide services for the automotive, industrial, and medtech industries. 

Capabilities: 3D printing

10. HLH Rapid

Location: Leeds, UK

Founded:

HLH Rapid offers 3D printing and rapid injection molding technology services. The company specializes in low-volume in-house rapid prototyping using multiple rapid manufacturing technologies to deliver parts to diverse industries. HLH Rapid offers services to the aerospace, telecommunications, consumer electronics, medical, and robotics industries. 

Capabilities: 

•  CNC machining
• 3D printing
• Vacuum casting
• Injection molding 
• Sheet metal work

11. Quickparts

Location: North America, United Kingdom, and Germany

Founded:

Quickparts provides on-demand manufacturing services using various technologies, such as injection molding, 3D printing, and cast urethane. The company offers full product lifecycle support, from initial design consultation to prototyping and final production. Quickparts provides services to various industries, including automotive, medical, electronics, and energy and gas. 

Capabilities: 

•  Injection molding
• SLA
• Selective laser sintering
• Cast urethane
• Sheet metal
• Direct metal printing
• Die casting

What To Look For in a Rapid Prototyping Company 

When choosing a prototyping company to partner with, consider these factors to find the best fit: 

Certifications

These certifications or credentials represent the company’s commitment to quality management systems and adherence to industry standards. By choosing certified prototyping companies, you ensure you partner with a company that can produce prototypes that meet your specifications and regulatory requirements. 

Some certifications to look out for include:

• ISO
• IATF  
• ISO .

Company Services and Prototyping Technologies

Evaluate the range of services your preferred company offers to ensure they have the capabilities to bring the vision of your prototypes to life. The best rapid prototyping companies offer a comprehensive suite of solutions, from CNC machining to rapid tooling, 3D printing, and more. This ensures you can partner with one company to get all the necessary solutions for your prototypes instead of having to manage a partnership with multiple companies at once. 

Various prototyping technologies, such as 3D printing, CNC machining, and vacuum casting, each have specific strengths and applications. A reliable company will guide you in choosing the best-fit technology for your product, ensuring that your prototypes are high-quality and tailored to your specific requirements.

Manufacturing Capacity 

Manufacturing capacity varies among rapid prototyping companies. Some specialize in low-volume production—ideal for testing, validation, or market entry—while others handle large-volume production for mass distribution. 

Assessing a company’s manufacturing capacity is essential to meet your project’s volume and timeline requirements. A reliable provider should scale production as needed, whether for a few prototypes or a larger batch.

Company Pricing 

Finding a balance between cost and quality is crucial, so look for a company that offers competitive pricing without compromising quality. A good rapid prototyping company should be able to provide detailed quotes that include the pricing of materials, production, finishing processes, and shipping. 

More to Know About Rapid Prototyping Companies

Some more things to know about rapid prototyping companies include:

Who uses rapid prototyping?

Rapid prototyping is used by manufacturers and businesses across various industries, including automotive, aerospace, healthcare, industrial machinery, and consumer electronics. These sectors use rapid prototyping to test out product design ideas, create functional prototypes, and accelerate product development cycles. 

Who is the father of rapid prototyping?

Charles “Chuck” Hull, the inventor of SLA 3D printing technology, is also recognized as the father of rapid prototyping. His invention of SLA facilitated the creation of the first-ever 3D-printed part. This laid the foundation for rapid prototyping and shaped the manufacturing industry forever. 

Work With The Best Rapid Prototyping Company 

With many rapid prototyping companies available, selecting the right partner can significantly influence the success of your product development journey. Choosing the best means choosing a company that offers a diverse range of capabilities, scalability, competitive pricing, and unbeatable customer service. 

UPTIVE Advanced Manufacturing stands out as a leader in the manufacturing industry, offering rapid prototyping solutions that enable the production of complex and precise parts. These solutions range from advanced additive manufacturing solutions like DMLS, SLS, and SLA to CNC prototyping and sheet metal prototyping. 

With these rapid prototyping technologies and an experienced team of expert engineers, UPTIVE enables the production of fully-functional prototypes and production-quality parts at incredible speed.

UPTIVE offers unmatched material matching capabilities, providing expert guidance to ensure your prototype is created with the best materials for your application and production needs. The team of experts works closely with you to explore concepts quickly, getting them to market faster, while maintaining high quality and consistency throughout the process.

With UPTIVE, you get fast, personalized service, a quick and easy quoting process, and long-term partnerships focused on innovation–all without compromising on the precision and quality you need to scale your projects efficiently.

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