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The inestimable value of prototyping in the design process

Prototyping is far more than just a step in the design process. It is a way of thinking. By bringing ideas into a tangible form, assumptions can be scrutinised, concepts validated and development decisions validated. A prototype serves as a bridge between the abstract world of sketches, CAD models and concepts and the physical reality in which a product must actually exist.

Possible applications of prototypes

The fields of application are extremely diverse. Designers and developers use prototypes to test form, function and usability at an early stage. Haptics, ergonomics and user interaction can thus be experienced in a depth that digital representations alone cannot achieve. Technical feasibility also becomes visible at an early stage: even simple models show whether mechanisms function smoothly, components interlock correctly or material thicknesses need to be adjusted. A prototype also improves communication within the team, as everyone involved can refer to a common, tangible model. Equally important is the opportunity to obtain direct feedback from users, stakeholders or investors. Iterative feedback flows directly into the next design round, which minimises risks and prevents costly errors in late project phases.

Prototyping is more than just a step in the design process

It is a philosophy that enables companies to quickly and cost-effectively transform their visions into tangible realities. By creating prototypes, teams can visualise, test and refine their ideas long before they invest significant resources in final production. This approach not only minimises the risk of bad investments, but also promotes a culture of innovation and continuous improvement.

An effective prototype does not have to be complex

Even the simplest models can provide valuable insights into the user experience and functionality of a product. From paper models to advanced digital mockups, prototyping allows startups to gather feedback from users and incorporate it directly into product development. This iterative approach not only helps to create a product that meets market needs, but also saves time and money.

3D printing as the engine of modern prototyping

In recent years, 3D printing has significantly expanded the possibilities of prototyping. Stereolithography (SLA) in particular impresses with its precision, surface quality and dimensional accuracy. Unlike the FDM process, which is primarily suitable for quick and cost-effective rough models, SLA produces realistic models that are not only visually appealing but also functional. The almost invisible layer lines and isotropic mechanical properties make SLA an ideal technology for detailed visualisation objects, fit tests and functional applications.

Focus on the Nexa3D XiP

The Nexa3D XiP is an impressive example of the professional use of SLA. It combines the performance of industrial systems with the compactness of a desktop device. Thanks to the patented LSPc technology, the XiP achieves printing speeds that far exceed those of conventional SLA systems. High-resolution prototypes can be produced in just a few hours, which significantly speeds up the entire iterative process. Another particularly valuable feature is the open material platform, which enables the use of a wide range of resins - from high-temperature resistant to flexible and biocompatible variants. This allows the system to be flexibly adapted to the requirements of different industries, whether in product design, medical technology or consumer electronics.

SLA printer XIP from NEXA 3D. Printing these parts takes 2 hours. The quality and accuracy is very close to injection moulded parts.

Prototyping also promotes a culture of teamwork

By involving everyone involved in the design process at an early stage, from engineers and designers to marketing specialists, a common understanding of the product and its goals is created. This interdisciplinary collaboration is often the key to overcoming challenges and achieving innovation.

Case study thingdust

We were able to develop and design the housing for their sensor for the successful start-up thingdust. With the help of high-resolution 3D printing, we were able to test the feel of fine structures as well as how the lid clicks into the main housing. The final injection moulded parts came out exactly as expected. No adjustments to the injection moulding tools were necessary.

Prototype of the housing of thingdust from the SLA 3D printer.

Final injection-moulded housing from thingdust.

Conclusion: A strong lever for innovation

Prototyping is not an optional extra, but a central component of modern product development. In combination with high-precision 3D printing, as is possible with the Nexa3D XiP, it unfolds its full potential: ideas are not only visualised, but also made tangible, tested, improved and further developed with real user feedback. This makes prototyping a powerful lever for bringing innovations to market faster, more reliably and more convincingly.

#Prototyping #Startup #Innovation #Industrial design

Use prototyping as a strategic lever - for creativity, efficiency and market success

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