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You’re struggling to create a prototype with complex geometries. What materials should you use?

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If you're an industrial designer, you know how challenging it can be to create a prototype with complex geometries. You want to test your design ideas, but you also need to consider the feasibility, cost, and quality of your materials. How do you choose the best materials for your prototyping needs? In this article, we'll explore some of the most common and effective materials for prototyping with complex geometries, and how to use them in your design process.

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Mikaia Valison

Mechanical Design Engineer
Shahzad Waseem Akbar

Engineering Graphics CAD Designer

1 Cardboard and foam

Cardboard and foam are cheap, easy to cut, and flexible materials that you can use to quickly sketch out your design ideas. You can use cardboard and foam to make rough models of your product, and experiment with different shapes, sizes, and features. Cardboard and foam are also great for testing ergonomics, user interaction, and functionality. However, cardboard and foam are not very durable, accurate, or realistic, so you'll need to use other materials for more refined prototypes.

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Shahzad Waseem Akbar

Engineering Graphics CAD Designer
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The plastic is one of the best material and its used commonly to create different types of prototypes. Plastic is also a durable, flexible, and cheap material.

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Mikaia Valison

Mechanical Design Engineer
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As a prototype, to get the first idea of how the product will look like; cardboard, wood and foam can do the job. In addition, these materials are easy to manipulate. But, due to the existence of 3D printer and CNC machine, we can use this technology for prototyping. In this case, the idea should be turned into a digital design for 3D print or CNC. In this case, other materials are available. But it is a more expensive.

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2 3D printing

3D printing is a popular and versatile method for prototyping with complex geometries. You can use 3D printing to create detailed, precise, and functional models of your product, using a variety of materials such as plastic, metal, resin, or wood. 3D printing allows you to create prototypes that look and feel like the final product, and test them in real-world scenarios. However, 3D printing can be expensive, time-consuming, and limited by the size and resolution of your printer.

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Mikaia Valison

Mechanical Design Engineer
(已编辑)
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One of the advantages of the 3D printing is that it can create any shape that you like. The most challenging part is in design. Nowadays, we can use even metal for 3D printing with SLS printer. So 3D printing process is versatile.

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3 CNC machining

CNC machining is another technique for prototyping with complex geometries. CNC machining involves using a computer-controlled machine to cut, drill, or carve your design out of a solid block of material. CNC machining can produce high-quality, durable, and accurate prototypes, using materials such as metal, wood, or acrylic. CNC machining is ideal for creating prototypes that need to withstand stress, heat, or wear. However, CNC machining can also be costly, noisy, and wasteful of material.

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Mikaia Valison

Mechanical Design Engineer
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Comparing 3D printing with CNC machining, the advantages of CNC machining are its accuracy and precision. So it is really helpful, especially for mechanical parts.

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4 Laser cutting

Laser cutting is a process that uses a high-powered laser beam to cut or engrave your design on a flat sheet of material. Laser cutting can create intricate, precise, and smooth prototypes, using materials such as paper, cardboard, wood, plastic, or metal. Laser cutting is suitable for creating prototypes that have flat or curved surfaces, or that need to be assembled from multiple parts. However, laser cutting can not create 3D shapes, and can burn or melt some materials.

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5 Casting and molding

Casting and molding are methods that involve pouring or injecting a liquid material into a mold that has the shape of your design. Casting and molding can create complex, detailed, and realistic prototypes, using materials such as rubber, silicone, resin, or wax. Casting and molding are useful for creating prototypes that have organic or irregular shapes, or that need to have a specific texture or color. However, casting and molding can be messy, difficult, and require making a mold beforehand.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Mikaia Valison

Mechanical Design Engineer
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Material choice depends on products we want. For a new product, we usually do many prototype before a final product. That's why for the 1st prototype especially, we tends to use material such as cardboard, wood, foam and recycled material that can be manipulate easily.

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You’re struggling to create a prototype with complex geometries. What materials should you use?

1

2

3

4

5

6

1 Cardboard and foam

2 3D printing

3 CNC machining

4 Laser cutting

5 Casting and molding

6 Here’s what else to consider

Industrial Design

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You’re struggling to create a prototype with complex geometries. What materials should you use?

1

2

3

4

5

6

1 Cardboard and foam

2 3D printing

3 CNC machining

4 Laser cutting

5 Casting and molding

6 Here’s what else to consider

Industrial Design

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