Rapid prototyping is used in product development to quickly create preliminary models. In thermoforming, rapid prototyping offers numerous advantages for producing high-quality prototypes efficiently and cost-effectively.
Sarah Guaglianone
Updated on June 15, 2026
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Rapid Prototyping, also known as Fast Prototyping, refers to the process of quickly and efficiently creating physical models or prototypes of a component or assembly based on three-dimensional CAD/construction data. The prototype serves as the first version of the product, which is thoroughly tested and revised if necessary before mass production.
There are four primary Rapid Prototyping methods in thermoforming, depending on the purpose of the sample. The following sections provide an overview of these methods.
Using 3D-printed thermoforming molds is common for testing critical segments of thermoforming processes. However, due to the high temperatures and mechanical stresses involved in thermoforming, only a small number of samples can be produced from a 3D-printed mold.
| The benefits of rapid prototyping using 3D printing | Disadvantages of rapid prototyping using 3D printing |
|---|---|
| 3D-printed tools are often cost-effective | Depending on the process used, 3D-printed parts have a distinctive surface texture which will be visible on the surface of the deep-drawn part if left untreated. Optical parts are therefore almost automatically ruled out for testing or demonstration purposes. Furthermore, the layered process used in FDM does not allow for the creation of realistic edges and radii, which further diminishes the results’ significance |
| Rapid fit testing of tray mould cavities | Some materials, such as PP, can only be moulded to the highest standard using temperature-controlled production moulds |
Ureol is a moulding material used in model making. Moulds made from Ureol can be used to produce either individual components or the entire finished product. The result often closely resembles mass-produced deep-drawn parts made using aluminium moulds.
Although the milling times for producing Ureol moulds are comparable to those for aluminium, the material is more cost-effective. However, due to Ureol’s lower heat and pressure resistance, only a limited number of samples can be produced.
The result is a prototype optimised for 3D printing, which takes only slightly longer to produce and costs only slightly more.
| Advantages of rapid prototyping with sample tools made from Ureol | Disadvantages of rapid prototyping with sample tools made of ureol |
| The samples produced are almost ready for series production, but show slight differences in quality compared to aluminum tools. | Additional costs: The Ureol tool only serves as an intermediate step prior to the production of the series tool. |
| The price is only about 20-30% of the price of a production tool, depending on the contour and complexity of the milling work. | The series tool is only manufactured after approval, which extends the project schedule by another 2-3 weeks. |
A single-cavity aluminium die provides an optimal reproduction of your deep-drawn part and offers cost savings compared to mass production. This can be achieved, for example, by using a simple die instead of a multi-cavity die.
Please note: The prototype mould is an intermediate step towards the production aluminium mould, and the additional time required for its manufacture must be taken into account in the project planning.
Testing a sub-segment using production-specification moulds yields the most realistic indication of the final production result. Where possible, the lessons learnt should be generalisable from the sub-segment to the entire tray.
| Advantages | Disadvantages |
| Closely replicates serial production quality | Additional production step delays final mold approval by 2-3 weeks |
| More affordable than a full-scale production mold | / |
| Can be adjusted for final production after approval | / |
The aluminum series production tool is also used to manufacture release samples. The deep-drawn parts produced using this tool are manufactured under optimal conditions in terms of elongation, heat, and cooling behavior.
The production rate per unit of time is a decisive factor in terms of price, particularly for medium to high production volumes, which is why large multi-purpose tools are often used.
Applications of production tool prototypes
In terms of production time, production tooling is, of course, the prototyping method that takes the longest. It is therefore primarily used to approve the production product prior to the start of series production – not necessarily for the empirical identification of areas relevant to testing, as with prototype variants 1–3.
| Advantages of rapid prototyping using production tools | Disadvantages of rapid prototyping using production tools |
|---|---|
| High-quality production of deep-drawn parts | Potential costs for reworking the production mould |
| No additional tooling costs before the start of series production | Production moulds take the longest to manufacture, so it is advisable to opt for a simplified version when samples are needed urgently |
| Samples are usually included in the price of the production mould | / |
| Saves time, as no additional approval steps are required | / |
Rapid prototyping using deep-drawing is used in a wide range of industries, including:
Rapid prototyping in deep drawing offers a wide range of options for producing high-quality prototypes of parts and components quickly and cost-effectively. By combining speed and flexibility, the rapid prototyping process streamlines product development and enables formary to bring innovative products to market more quickly.
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Rapid prototyping in thermoforming is the rapid production of plastic prototypes based on 3D CAD data to test form, fit, and function prior to mass production.