Rapid Prototyping in Thermoforming – Definition, Benefits & Processes
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 in deep drawing – the key points at a glance
Rapid prototyping in deep-drawing speeds up development and reduces tooling changeover costs.
There are four rapid prototyping methods used in deep drawing: 3D printing, urethane, partial-segment moulds and production moulds.
Rapid prototyping is used in particular in the sectors of the automotive, medical technology, robotics and packaging industries.
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.
What is the Purpose of Rapid Prototyping?
Speed: Rapid Prototyping enables the production of prototypes in the shortest possible time, significantly accelerating the development process.
Flexibility: The process allows for quick modifications and corrections to prototypes, improving the final product.
Shorter Time-to-Market: The production and delivery of prototypes are significantly shortened, allowing products to be launched faster.
Benefits of Rapid Prototyping
Early detection of design improvements
Cost efficiency
High precision through computer-aided design
Reduced risk of costly errors
Ability to present physical prototypes and gather feedback
Cost-effective integration of customer requirements
What Types of Rapid Prototyping Methods Exist in Thermoforming?
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.
Rapid Prototyping with 3D-Printed Molds
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.
3D-printed prototypes
Maximum number of samples: 1-3 pieces
Production time (best case): 3-5 working days
Cost:€€€€€
Application Areas:
Testing form-fit accuracy of tray cavities
Rapid production of prototypes within a few days
Small batch production in standard material
Advantages vs. Disadvantages of 3D-Printed Molds
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
Rapid Prototyping with Ureol Sample Molds
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.
Ureol tool prototypes
Maximum number of samples: 5-10 pieces
Production time (best case): 1-2 weeks
Cost:€€€€€
Applications of Ureol tool prototypes
The result is a prototype optimised for 3D printing, which takes only slightly longer to produce and costs only slightly more.
Overview of the advantages and disadvantages of rapid prototyping using Ureol moulds
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.
Rapid prototyping using a partial-segment production mould
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.
Sub-segment production tool prototypes
Maximum number of samples: unlimited
Production time (best-case scenario): 2–3 weeks
Price: €€€€€
Areas of application: sub-segment – production tooling and prototypes
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.
Overview of the advantages and disadvantages of rapid prototyping using partial-segment production moulds
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
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Can be adjusted for final production after approval
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Rapid prototyping with series production tools
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.
Production tool prototypes
Maximum number of samples: unlimited
Production lead time (best-case scenario): 2–6 weeks (depending on size, design and number of compartments; up to 10 weeks may be required for special components)
Price: €€€€€
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.
Overview of the advantages and disadvantages of rapid prototyping using production tools
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
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Saves time, as no additional approval steps are required
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Rapid prototyping applications
Rapid prototyping using deep-drawing is used in a wide range of industries, including:
Automotive: Prototypes of vehicle components such as dashboards, door panels and bumpers can be produced quickly and cost-effectively.
Medical technology: The production of prototypes of medical devices and housings enables manufacturers to develop and test new products quickly.
Packaging industry: Prototypes of packaging and plastic containers can be produced to test their functionality and aesthetics before they go into mass production.
Robotics: In robotics, the deep-drawing process enables high-speed prototyping, with the ability to make adjustments quickly.
ℹ️ Would you like to find out more about the applications of thermoformed parts? Then read our article Thermoformed plastic parts in use.
Rapid Prototyping in Deep Drawing – A Summary
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.
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.
3D-printed tools are only suitable for representative samples to a limited extent, as they differ from the series production process in several ways:
Main differences:
Surface quality: The layer structure of 3D printing is transferred to the thermoformed part, which means that visually representative series parts cannot be realistically reproduced this way.
Geometry: FDM processes do not produce edges and radii as precisely as milled series tools.
Temperature control: 3D-printed tools cannot be temperature-controlled, which leads to different results, especially with materials such as PP.
Durability: Only 1–3 samples are usually possible, as the tool cannot withstand the temperatures and loads for long.
For series-like approval samples, a series tool made of aluminum is therefore recommended. It provides realistic results in terms of surface quality, stretch behavior and material properties.
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