Each method for creating plastic prototypes has its own characteristics, and choosing the right one is indeed crucial.
| Manufacturing Method | Suitable Scenarios | Main Advantages | Main Disadvantages |
|---|---|---|---|
| CNC Machining | Appearance Verification, Structural Testing, High-Precision Requirements | High Precision, Good Strength, Excellent Surface Quality | High Cost for Complex Structures |
| SLA (Stereolithography) 3D Printing | Complex Shapes, Fine Details, Rapid Prototyping | Fast Print Speed, Smooth Surface, Strong Detail Representation | Limited Material Properties, Potential Long-Term Aging |
| Silicone Molding | Small Batch Replication (Tens to Hundreds of Pieces) | Low Cost for Small Batches, High Efficiency, Wide Material Selection | Lower Accuracy, Limited Mold Lifespan |
| Injection Molding (A-Mold) | Batch Sizes from Hundreds to Thousands | Fast Molding Cycle Time | High Mold Cost, Long Mold Lead Time, Not Suitable for Mold Modifications |
How to Choose the Right Prototype Process
When selecting a prototype manufacturing method, you can focus on the following four aspects:
- Consider Accuracy and Appearance
If the prototype is used for precise assembly verification or requires high-quality surface treatment (like painting, plating), CNC Machining is the preferred choice, as it maintains the best performance of materials like ABS. - Consider Mechanical Properties and Durability
For functional testing (such as bearing certain loads or fatigue testing), the material authenticity and strength of the prototype are crucial. CNC Machining uses real engineering plastics (e.g., ABS, PC), and the parts produced have mechanical properties closest to the final product. In contrast, 3D printing (SLA, SLS) mostly uses photosensitive resins or sintered powders, whose mechanical properties and durability are generally inferior to CNC machined parts. - Consider Cost and Efficiency
- Single Piece or a Few Prototypes: For verifying design concepts while pursuing speed and low cost, SLA 3D Printing holds significant advantage.
- Small Batches (Tens to Hundreds of Pieces): The per-unit cost of Silicone Molding is usually much lower than CNC machining or 3D printing.
- Single, Highly Complex Prototype: If the part has extremely complex internal structures, SLS technology offers advantages due to not requiring supports, saving material in such cases.
- Consider Batch Size
When dozens or more sets of prototypes are needed, the cost-effectiveness of Silicone Molding becomes apparent. If the batch size increases further (e.g., over a thousand sets), considering Injection Molding becomes necessary.
Focus on Post-Processing and Surface Effects
After the prototype is manufactured, post-processing is usually required to achieve the desired effect:
- Prototypes made by CNC Machining and SLA Printing are very suitable for subsequent surface treatments such as spraying, screen printing, electroplating, etc., and can achieve an appearance very similar to the mass-produced product.
- Prototypes made by SLS Printing usually have a rougher surface and require additional processes like sanding or infiltration to improve it.
- Processes like Vacuum Metallizing can provide a metallic feel without affecting signal transmission, often used in electronic products like mobile phones.