Common Mistakes of Rapid Prototyping Suppliers & How to Avoid Them

Rapid prototyping is a critical phase, but suppliers can sometimes make errors that lead to delays, cost overruns, and poor outcomes. Here are the key pitfalls and their solutions.

1. Mistake: Poor Communication and Unmanaged Expectations

• The Error: Suppliers fail to communicate design limitations, potential delays, or cost changes clearly. They assume the client understands technical jargon and processes.

• How to Avoid:

• For Suppliers: Provide regular, proactive updates. Use simple language to explain technical issues and offer Design for Manufacturability (DFM) feedback early on.

• For Clients: Choose a supplier that emphasizes communication and provides a dedicated project manager.

2. Mistake: Selecting the Wrong Technology or Material

• The Error: Choosing a prototyping method (e.g., FDM, SLA, SLS) or material based on habit or cost alone, rather than the part's specific function, required strength, or surface finish.

• How to Avoid:

• For Suppliers: Ask detailed questions about the part's purpose (e.g., form, fit, or functional testing) and recommend the most suitable technology and material.

• For Clients: Clearly state the prototype's requirements and be open to the supplier's expert recommendations.

3. Mistake: Ignoring Design for Manufacturability (DFM)

• The Error: Simply printing the client's CAD file without reviewing it for common issues like unsupported walls, incorrect wall thickness, or problematic features that can't be built accurately.

• How to Avoid:

• For Suppliers: Always conduct a formal DFM analysis and send a report to the client before starting production, suggesting modifications.

• For Clients: Work with suppliers who offer a free DFM analysis—it saves time and money in the long run.

4. Mistake: Inadequate Post-Processing or Finishing

• The Error: Applying inconsistent or low-quality finishing (sanding, painting, smoothing). This makes the prototype look unprofessional and fails to represent the final product's intended appearance.

• How to Avoid:

• For Suppliers: Establish and follow strict quality control standards for post-processing. Provide clear samples of different finish options.

• For Clients: Specify your desired finish level and, if possible, approve a finish sample beforehand.

5. Mistake: Inaccurate Quoting and Project Management

• The Error: Providing an initial quote that doesn't account for material, machine time, and labor for post-processing, leading to surprise charges or project delays.

• How to Avoid:

• For Suppliers: Use a detailed and transparent quoting system that breaks down all costs. Manage the project pipeline effectively to avoid overbooking machines.

• For Clients: Be wary of quotes that seem too good to be true. Ask for a detailed cost breakdown.

In summary, the best way to avoid these common errors is to partner with a communicative, experienced, and transparent rapid prototyping supplier who acts as a consultant rather than just an order-taker.