Functional prototype
For the bench: fit, load and assembly.
Rapid prototyping with 3D printing
Functional, appearance and assembly validation prototypes, 3D printed. From the CAD file to a part on the bench, before the mould is released.
A mistake on a prototype costs one print
Rapid prototyping means 3D printing a part that still lives in CAD to check shape, fit and function before tooling. Tesseract 3D prints in FDM and SLA resin, true to the file, at ±0.1 mm tolerance.
A mistake in the tooling costs the project schedule. That is the maths that makes a 3D round worth it before releasing a mould, a fixture or a pilot run. The kind of prototype changes the technical choice: a mechanical test needs a tough material and accuracy; a presentation needs a surface ready for paint.
The three kinds
Each answers a different question about the same part.
Engineering recommends the material in the review.
Appearance prototype
For the meeting: shape, colour and finish.
Assembly validation
For the assembly: clearance, access and sequence.
No CAD file?
Photos from several angles and the main measurements also work. The engineering review tells you what can be done with them.
Functional, appearance or assembly?
What the prototype has to answer decides the material and the finish.
| Kind | What it checks | Typical material | Finish |
|---|---|---|---|
| Functional prototype | Load, fit and use on the bench | Engineering ABS and PETG | Only where the function needs it |
| Appearance prototype | Shape, colour and grip | Resin for detail, FDM for volume | Sanding, primer and paint |
| Assembly validation | Clearance, access and assembly sequence | ABS and PETG; PLA for a quick check | On request |
Which prototype should you order?
Pick the question closest to yours. The answer points to the right page.
Pick a question and the answer shows up here.
You need a functional prototype: engineering material, true to the CAD.
See functional prototypesYou need an appearance prototype: finished, primed and painted.
See appearance prototypesYou need assembly validation: the assembly on the bench before the mould.
See assembly validationWhere a prototype becomes a solution
Prototypes also work away from the bench.
Training
Printed parts so the team can rehearse assembly for a new line.
Corporate gifts
The new product, painted, on the decision maker’s desk.
Trade shows and events
A launch on the booth, before the first batch.
Sales demonstration
A sample the client fits into their own assembly.
Common questions
How many rounds does a prototype usually take?
It depends on what the first one reveals. The method is simple: each fix becomes a new print instead of a mould change.
Can I order functional and appearance prototypes from one file?
Yes, and it is common: the functional one goes to the bench and the appearance one to the meeting.
Can a printed prototype be used for certification tests?
It does not replace the part from the final process. It finds the mistake earlier; standard tests use the production part.
Do you print in engineering materials?
Yes. Engineering ABS and PETG for parts that work, and resin for fine detail. The choice comes in writing with the engineering review.
Trade showThe scale piece goes to the booth instead of the real machine.
TrainingThe machine that cannot stop goes into the classroom, cut open.
Sales visitThe rep carries in a suitcase what would never fit in one.
A design before the mould?
The engineering review comes back within 24 business hours, with the kind of prototype, material and lead time.