3D printing for iterative product development
From the first form check to pre-series parts: we support development projects with short print cycles, so every revision reaches your desk quickly and design freeze rests on tested data.
First iteration usually back in 2 to 3 working days
Stages in the development process
Each development phase places different demands on the printed part, from pure appearance to load bearing function in the target material.
Form models
Early tactile models to assess proportions, grip and appearance, usually in PLA for short print times and low cost.
Fit checks
Verification of tolerances, interfaces and assembly against real mating parts, before more expensive tooling or series parts are procured.
Functional prototypes
Parts in the intended series material for load, temperature or endurance tests under realistic conditions.
Pre-series parts
Small batches for user trials, approval preparation or market launch, with a surface finish close to the planned end product.
Suitable materials
Early form models mostly work fine in PLA, while functional prototypes and pre-series parts use whichever material comes closest to the planned series solution.
- PLAFast, affordable prototyping and visual parts.
- PETGTough, food-safe-capable everyday workhorse.
- ABSClassic engineering ABS - strong, affordable, easy to finish.
- PCPolycarbonate - high impact, high heat, transparent option.
- PA12-CFCarbon-filled nylon 12 - the metal replacement workhorse.
- ASAThe outdoor specialist - ABS mechanics with true UV stability.
Details needed at each development stage
- 01Current development stage: form check, functional test or pre-series, so material and post-processing match.
- 02Planned series material and process, even if the prototype is first printed in a different material.
- 03Mating parts or assemblies the part must fit, ideally provided as a STEP file.
- 04Planned tests: load, temperature, UV or chemical exposure, so we can narrow down the material accordingly.
- 05Timeline to the next milestone, so we can pace the iteration loop accordingly.
From the first form model to a reliable pre-series
Product development thrives on fast loops. The longer an iteration takes, the more expensive a wrong decision becomes once it surfaces late. We align our process so a form model or fit check reaches your desk within a few working days, letting a development team learn from physical parts weekly instead of monthly. This matters especially early on, when many details remain open and a print trial is cheaper than a long discussion at a screen.
The switch from prototype to series material is a point where many projects lose time. A part that fits cleanly in PLA can turn out noticeably different in PA12-CF or PC due to different shrinkage and stiffness. We recommend printing in the intended series material at the latest from the functional test stage onward, even if the earlier form check ran more cheaply in PLA. That way tolerance deviations become visible before they get locked into tooling or fixed specifications.
For planning revision loops it helps to define upfront what each round is meant to verify, instead of changing everything at once in every iteration. When form, fit and function are tested separately, a deviation can be traced to a clear cause. For the pre-series stage we then send parts in the series material with surface treatment close to the planned end product, so user tests and internal sign-offs rest on representative samples.
Manufacturing data at a glance
- Location
- Schleswig, Germany
- Part size
- up to approx. 250 x 250 x 250 mm, larger parts split and joined
- Quantities
- 1 to several thousand, no minimum order quantity
- Tolerances
- approx. ±0.2 mm for PLA, PETG and carbon grades, ±0.3 mm for ABS, ASA and PC
- Layer height
- 0.10 to 0.30 mm
- Materials
- 20 engineering filaments from PLA to PA12-CF and PC FR
- File formats
- STEP, STL, 3MF, OBJ, IGES up to 200 MB
- Lead time
- 2 to 4 working days for samples, 4 to 15 working days for series
Upload Your File for Instant Pricing
Receive fast pricing and manufacturing feedback in minutes. STEP, STL, 3MF and OBJ supported.
Product development FAQ
- How many iterations are typical before design freeze?
- It depends on the part, but two to four printed revisions are realistic for most mechanical parts: a form check, a functional version, a version in series material, and possibly a final correction.
- At what point should printing switch to series material?
- As soon as form and fit are settled, functional tests should run in the intended series material. A part that fits in PLA may show different shrinkage and stiffness behavior in PC or PA12-CF, shifting the fit again.
- What should we provide for the first iteration?
- A STEP file is enough for the first form check. For functional prototypes, information on mating parts, forces and environmental conditions helps us choose material and wall thickness accordingly.
- Can pre-series parts go straight to customers or test users?
- Yes, pre-series parts in the series material suit user testing once look and function already approach the planned end product. For visible series-like finish we recommend surface post-processing.
Read next
Engineering Material Selection Guide for FDM 3D Printing
The best material is not the strongest one. It is the one that matches the environment, the mechanical requirements and the production goals of the part.
Why Larger FDM Orders Fail (And How to Avoid It)
FDM forgives at low volumes and punishes at high ones. Why scaling FDM is a process problem, not a printer problem.
Handing over design data properly: what a manufacturer actually needs
Most delays in contract manufacturing do not happen at the machine, they happen in the data handover. Four pieces of information prevent almost every query.