Functional Prototyping Overview
From CAD files Fortus 3D Production Systems produce thermoplastic parts that are used for conceptual prototyping, design verification and functional testing. The benefits of using an additive fabrication system for prototyping include streamlining the development process, reducing costs, and getting to market faster.
Why manufacture prototypes with Fortus 3D Production Systems?
Reduce Time
- Accelerates product development by bringing ideas to life faster and less expensively
- Enables you to correct errors early in the design process and before the tooling stage
- Reduces time-to-market
Reduce Cost
- Better-predict end product performance and gain certification confidence with high-tolerance parts
Find problems early in design cycle, before the cost to correct them rises- Eliminate one or more rounds of tooling by proving out the product's design before it reaches tooling
Other Benefits
- Multiple iterations of design produce better end product
- Gain early approvals for required testing such as UL and CE certification
- Easy to use system with no messy liquid vats or powder containers to maintain
- The Fortus technology process is simple, safe and produces thermoplastic parts in hours, not weeks
How are Fortus thermoplastic prototypes used?
- Form and fit models and testing
- Concept models
- Functional testing in real-life conditions
- Visual aids for tooling, engineers, and accurate bids
- Sharing concepts with management, customers, sales, marketing and manufacturing
- Communication models between departments and companies
- Samples for marketing and sales
- Product research
The FORTUS Production Process
Fortus systems are built on FDM technology, which is simple and safe. They can manufacture production-grade thermoplastic parts that are ready for form, fit, and functional testing.
- Pre-Process - Load the part’s STL file (CAD data) into Insight pre-processing software.
- Manufacture Parts- System builds part in thermoplastic material one layer at a time on precise tool paths.
- Remove Supports - Remove temporary support structures in a hands-free soluble support tank.
Optional - Finishing techniques like painting, electroplating and wood grain dipping can be applied to make the prototype look like a final production piece.
Fortus customers who are saving time and money using Fortus 3D production systems to build prototypes in-house. Read their stories below.
Akaishi – 99% tooling cost reduction. 100% confidence.Using FDM for models, prototypes, and tooling, Akaishi gets a payoff in lead time, cost avoidance, and product quality.
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Access Business Group
“Some of the reason we wanted to bring RP in-house was to be able to define the aesthetics more quickly. And we also wanted to get testable models faster. I guess the bottom line was faster!” Eric Bartkus, Access Business Group
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Bell Helicopter creates 42 conduit models in just over two days to test with Osprey hybrid aircraft.
Aerospace technicians are a demanding bunch and those at Bell’s prototyping lab appreciate the clean post-processing of Fortus prototypes. They note other processes require three times more post-processing time than in actual part creation. Plus, Fortus systems allows for more iterations and better-designed components.
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Bullard
“Because of the concept models we didn’t have to guess if the customer would like the T3– we knew from the very beginning.”
Eric Bielefeld, Bullard
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Fortus systems reduces Dana Corp’s product development prototype process costs by 90 percent.
The complicated assemblies produced by this automotive supplier were time and cost prohibitive via conventional methods. Fortus prototypes proved accurate; provided specialized functionality; and were ready in just days. Plus, optional color differentiation helped better evaluate in-use part performance.
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Diebold’s Fortus ATM prototype holds up under sleet, snow, extreme temperatures and 95% humidity.
After a year-long test under temps ranging from – 5◦ F to 95◦ F and other weather extremes, Diebold proves out its designs with prototypes tough enough for machine function tests. Other benefits include lowered tooling costs, improved products and more accurate predictions of performance of injection molded parts.
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Ducati races forward with engine design process fueled by in-house Fortus Systems.
Speed, durability and functionality are critical in motorcycle engines and the engineers at Ducati found all of this by using its two Fortus machines to create a winning engine in just eight months, versus 28 months when prototype needs were outsourced to a service bureau.
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Hanil E-Hwa - FDM - A Crucial Tool for Auto Interiors
FDM Helps Deliver Shorter R&D Times and High Quality
“FDM has advantages that include part strength and ease of modification. These are important traits when assembling prototypes for confirmation of quality and suitability of design.” Choi Hae Seok, Hanil E-Hwa
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Hyundai Mobis’ Fortus system provides ROI in less than 30 months; delivers dimensional accuracy and faster design process.
An ABS plastic instrument panel prototype measured a deviation of just 0.75 mm over a length of 1382 mm, garnering accolades for the Kia’s fit and finish. Plus, 27 minor design flaws were discovered and quickly remedied with the functional prototype in place.
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Joe Gibbs Racing speeds ahead with Fortus parts taking design from concept to car in days.
Fortus prototypes -- ready in days, not weeks – help race team engineers speed ahead with design concepts that beat out the competition. Not only are prototypes built quickly; they are tough enough to go from concept to car – even the engine block – for quick evaluation.
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Logica’s medical device prototype used for actual surgeries; convinces physicians of tool’s potential.
Often when a new medical device is introduced, users are skeptical as they can’t see it in action. Logica dramatically increased user understanding and acceptance of its new technology with a strong, heat-resistant prototype assembly created through Fortus and used in more than two dozen surgeries as a functioning prototype.
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Logitech creates optimal design with help of Fortus functional prototypes, and improves part strength 273%.
Using Fortus to perform functional tests helped Logitech find the optimal design for a Bluetooth headset. Logitech engineers say Fortus systems were critical to their success, and using formulas and CAD models alone, might never have led to the optimal design. The functional tests improved the microphone boom strength by 273%.
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Medtronic’s Sofamor Danek prototype lab cuts delivery time for surgical instruments.
With surgeons needing working instruments ASAP, the in-house prototyping system employed by Medtronic is a critical, easily justified aspect of its operation. The company cites lower costs, better communication through working prototypes and immediate redesign options as just a few of its benefits.
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Parker Hannifin – Racor Emissions filter prototype handles V8 engine heat near 400°F and hot gasses.
Using the FDM process and PPSF plastic – which handles heat near 400°F – Parker Hannifin created an emissions filter prototype tough enough to successfully mount and test on a V8 engine for 78 hours.
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Polaris praises Fortus for reducing tooling costs by $60,000 per part and speeding time to market. On average, tooled snowmobile parts previously took eight to 12 weeks, at about $60,000 each. Now, Polaris’ in-house FDM machine cuts the time to about two days with outstanding cost savings as a bonus. With PC-ABS materials, functional prototypes are tested and refined long before they hit the snow.Read Case Study | Download PDF
Steve Prentice Design, Ltd. reduce engine tooling costs by 75%
"With FDM, we can quickly evaluate design changes. When we commit to production injection-mold tools, we're confident they will be right the first time."
Steve Prentice, Steve Prentice Design, Ltd
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Toro sees savings of $500K and a 283 week reduction in product development time.
Over two years, for various projects, including this sprinkler, Fortus systems allowed Toro to reduce product development time by 283 weeks, and it saved $500,000 on tooling and service bureau costs.
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