From Prototype to Production: The Role of Design Modifications in Perfecting Your Part
The journey from prototype to production is rarely straightforward. At The 3D Shop, we know that even the best initial designs often require refinement to meet real-world demands. Our expertise lies in identifying these challenges and optimizing your designs to ensure functionality, durability, and cost-effective production—without compromising on quality.
Common Challenges in Prototyping
Prototypes are a critical step in product development, but they often highlight unforeseen issues that can derail production if not addressed early. A few examples of this could be:
Parts That Fail During Testing: Designs that look great in CAD can falter under real-world stresses. Prototyping helps reveal weak points that require reinforcement or redesign.
Designs Too Costly to Produce at Scale: Some prototypes are unnecessarily complex or include features that are difficult or expensive to replicate in large quantities.
Materials That Don’t Meet Durability Requirements: Using the wrong material can lead to breakage, warping, or wear, particularly in high-stress or high-heat applications.
At The 3D Shop, we address these challenges by taking a critical, collaborative approach to refining your design.
How We Modify Designs for Success
Step 1: Identifying Weaknesses
The first step is testing your prototype under conditions that mimic its intended use. Our goal is to evaluate every aspect of the design to pinpoint areas for improvement.
Example:
A client’s part, designed for heavy industrial use, failed during load testing due to weak joints. By modifying the joint structure and density (only available in 3D printing), we were able to significantly improve its strength without increasing production costs.
Step 2: Optimizing for Manufacturing
Prototypes often need to be adjusted to ensure compatibility with manufacturing methods. This includes:
Simplifying Complex Geometries: Designs with unnecessary complexity can be cost-prohibitive to produce at scale with traditional manufacturing methods. If your goal is to produce your idea in large volumes, we simplify these features without sacrificing functionality - even if those complex geometries could have been produced with additive manufacturing.
Adapting for Additive Manufacturing: Some designs, especially those with intricate internal structures, are better suited for additive manufacturing (3D printing). In these cases, we can optimize CAD files to ensure precision and minimize waste during printing.
Example:
Products with intricate internal channels or articulating joints originally required expensive machining or post processing and assembly. Designing the product with additive manufacturing in mind, we are able to produce these parts without the need for expensive machining or the labor costs that come with post processing and assembly while maintaining performance.
Step 3: Enhancing Durability
Durability often hinges on two factors: material selection and structural design.
Material Adjustments: We analyze whether the chosen material will meet durability requirements or if an alternative (e.g., Polycarbonate instead of PETG) would perform better.
Structural Reinforcements: Adding features that would normally be cost prohibitive in traditional manufacturing like ribs, fillets, or even internal structures that are only possible with 3D printing, can significantly increase a part’s strength and longevity.
Example:
A part we designed to fit perfectly into a tight space was able to be intentionally designed slightly oversized - but with a more flexible material - and with less dense internal structures in order to provide the proper amount of force, when paired with glues, to fill out the space and stay in place for its intended use.
The Role of CAD Design Modifications
At the heart of refining prototypes is CAD (Computer-Aided Design) modifications. These adjustments ensure that your part is not only manufacturable but also optimized for its intended purpose. At the 3D Shop, we use a variety of CAD tools which allow us to make adjustments in the best possible way - whether they are functional or cosmetic.
Key CAD Modifications We Perform:
Simplifying Assemblies: Consolidating multiple components into a single part where possible, reducing assembly time and costs.
Adding Draft Angles for Molding: Injection-molded parts require angled surfaces to allow easy release from molds. We add these features while maintaining dimensional accuracy.
Cosmetics and Branding: What good is your product if your customers forget who they bought it from? We are able to use our CAD software in several different ways in order to functionally advertise your brand when necessary in ways your clients will notice without inhibiting the function of your part.
Integrating Supports: For additive manufacturing, we modify designs to minimize the need for excessive supports, reducing material usage and post-processing time - which lowers cost.
Why Design Refinement Matters
The refinement process bridges the gap between concept and production. By addressing weaknesses, optimizing for manufacturing, and ensuring durability, we help you:
Avoid costly production errors.
Reduce waste and material costs.
Deliver a product that meets or exceeds performance expectations.
Ready to Perfect Your Design?
The journey from prototype to production doesn’t have to be daunting. With our expertise in design refinement, materials science, and manufacturing methods, we’ll ensure your part is ready for production—efficiently and sustainably.
Contact The 3D Shop today to discuss how we can optimize your prototype for success.
