Why quality equipment matters to cutting-edge prototyping

The rapid prototyping industry is incredibly efficient — and hugely competitive. Thanks to the internet, engineers can instantly upload their designs and receive a quote within hours. Depending on the manufacturing process, these parts can often be shipped just a few days later.

Perhaps the only problem for engineers and product designers is the sheer number of companies offering third-party manufacturing services. Across China and other parts of the world, a huge number of rapid prototyping companies, machine shops, and low-volume manufacturers are competing to provide the best, fastest service.

Engineers, therefore, need to find out what distinguishes one prototyping company from another. Guangdong’s BOEN Rapid's unique selling point is a suite of high-end manufacturing equipment not always offered by other low-cost prototyping companies.

Why quality matters in rapid prototyping

In the world of rapid prototyping, it’s tempting to assume that the two most important factors are speed and cost. After all, the faster a prototype can be delivered, the sooner a product can undergo testing, validation, and production. Faster rapid prototyping means a shorter time-to-market.

Cost would also seem to be a major factor. Most companies will understandably appreciate a smaller invoice from their prototyping partner, and one would expect engineers to prioritize low costs for prototyping and high quality for production, since nobody will see or use the prototype except company insiders.

However, there are many reasons why a bad prototype can have negative consequences for product designers. Quality matters at all stages of product design, and prototyping is no exception. Below are just some of the reasons why high-quality prototypes are beneficial.

• Final parts fidelity: Well-made prototypes — those made with skill using professional manufacturing processes — will closely resemble end-use production parts. This means that any testing and validation performed on the prototype will provide more genuine insight about the performance of the final part.

• Showcase potential: Product designers don’t just make prototypes for testing. They might also need a visual or functional prototype to show to investors or business partners. In such cases, the visual and mechanical quality of a prototype is virtually as important as the quality of the final parts, as the entire business proposal may depend on it. Quality machining, clean and smooth surfaces, and consistent coloration can all contribute to a successful demonstrator part.

• Bridge production: A high-quality prototype isn’t a dead end in the product development cycle. If the prototype is made to a high standard (using the kind of processes and materials that will be used for the final part), its design can be the basis for part production. In some cases, the prototyping company may even provide the first low-volume production run, saving the product designer money.

• First-time success: Cutting corners can shorten product development times, but it can also result in prototypes that are simply unusable. Prototypes made without care using low-quality equipment may not meet the designer’s specifications, requiring repeat orders that actually increase the total time and money spent.

In summary, high-quality prototypes provide many benefits. Although end-users won’t see them, quality prototypes can lead to effective testing, persuasive showcasing, and a smoother transition to production. 

Why high-end equipment is key to successful prototyping

We have seen above why it is important to carry out rapid prototyping to a high standard. But how does one ensure that prototypes ordered from a third party are in fact built to a high standard? 

One key factor is human skill. While many prototyping processes involve digital manufacturing — in which the part is fabricated by a computer-controlled equipment rather than by human hand — these processes still demand a high level of expertise. For instance, project managers require a broad knowledge of different processes, materials, and surface treatments, enabling them to instantly identify the ideal manufacturing solution for a design. These skilled professionals must also be able to read technical drawings (in both 2D and 3D) and understand geometric dimensioning and tolerancing to quickly ascertain the scope, complexity, and feasibility of a design. This degree of knowledge requires many years of training and experience. 

BoenRapid's machine floor. Credit: BoenRapid

All workers at the facility must possess a similar level of expertise in their designated role. Engineers must validate the proposal in terms of design for manufacturing (DfM), expert machine operators must set up the machines with the correct digital parameters and physical considerations (workholding, clamping, etc.), and finishing specialists must carry out processes like sanding and painting with a high level of manual skill. 

Another element to consider is the raw materials used for the prototype. While many designers use slightly less expensive materials for their prototypes — especially when working with metals — these materials affect the quality of the final prototype. A reliable prototyping company will be able to recommend material choices for a high-quality prototype that remains within the project budget. 

An equally important consideration for making quality prototypes is the quality of the manufacturing equipment. In virtually every area of manufacturing, there is a huge range of machinery available, from budget equipment to the best industrial-grade units used by the world’s most profitable companies. Take fused filament fabrication (FFF) 3D printing, for example. Entry-level machines can cost just a few hundred dollars, while industrial-grade systems with multiple extruders and supreme speed and accuracy often cost six figures.

At prototyping company BOEN Rapid, the decision was taken to use the best possible equipment to guarantee high-quality prototypes for all customers. This is made apparent in the company’s CNC machining offering, in which it uses 5-axis machines from world-leading hardware companies like DMG MORI (Germany) and HERMLE AG (Germany). 5-axis machining centers provide a much greater degree of geometric flexibility than traditional 3-axis machines and also require fewer setups, greatly reducing cycle times. However, due to the complex toolpath generation required by 5-axis machining, it pays to use only the best hardware and software to eliminate manufacturing errors.

The quality control stage of rapid prototyping also benefits from high-quality equipment. Here too BOEN Rapid has invested in the best metrology and inspection equipment available, using coordinate measuring machines (CMMs) from ZEISS (Germany) to guarantee that all prototypes meet design specifications within acceptable tolerance limits.

Part of BoenRapid's CNC floor. Image credit: BoenRapid

Working with BOEN Rapid

BOEN Rapid works with customers of all sizes from a broad range of industries, from automotive and aerospace to medical devices to consumer goods. Regardless of whether you need a single 3D printed prototype or 1,000 aluminum extrusions, BOEN Rapid will make your parts to the highest standards using its high-end equipment. Moreover, the majority of BOEN Rapid engineers have more than a decade of experience and, therefore possess the knowledge and skills required to realize even the most complex prototyping requirements.

Request a quote from BOEN Rapid to discover how this trusted company can become your go-to prototyping and low-volume manufacturing partner.