Rapid Prototyping
with RapidDirect

Rapid CNC machining, injection molding, sheet metal fabrication, 3D printing and vacuum casting services. Lead time as fast as 1 day.

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What is
Rapid Prototyping

Rapid prototyping quickly converts early-stage design concepts into physical models, offering a fast and cost-effective way to see ideas in reality. This approach is particularly effective through technologies such as 3D printing, CNC machining, and more, with the ability to deliver prototypes typically within 1-3 business days.

Opting for prototyping is essential for speeding up the design process while reducing the financial and operational risks associated with new product development. It enables thorough testing and refinement of designs, ensuring that each iteration is an improvement on the previous one. This process is critical for making informed decisions early in the development cycle, minimizing the risk of expensive alterations later on.

Our Rapid Prototyping
Services

Rapid CNC Prototyping Service

CNC machining, including both CNC milling and CNC turning, is an excellent choice for rapid prototyping when parts need to be assessed in their final material form. This method allows for prototypes to be made from fully dense stock, providing accurate and durable models. RapidDirect specializes in machining a broad spectrum of metals and plastics, ensuring versatility for your project requirements. Our rapid CNC prototyping services deliver high-quality machined prototype quickly, often in 1 day. This speed, coupled with our cost-effective pricing, allows engineers to order multiple prototypes at once, facilitating quick and thorough product evaluations.

Choosing RapidDirect for your CNC prototyping needs means benefiting from our expertise and commitment to precision. We provide various expedite options, ensuring that urgent projects are completed on time. Our market-based pricing model ensures affordability without compromising quality. With RapidDirect, you receive detailed and accurate prototypes that support rapid product development, from initial design to final production.

Maximum Part Size:

CNC Milling: 4000×1500×600 mm

CNC Turning: 200×500 mm

Standard Lead time: 1 day

Tolerance: 0.001 inches

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Rapid Prototype Injection Molding Service

Injection molding is a top choice for prototyping when you need highly durable and consistent parts for extensive testing. This method is perfect for high-fidelity product evaluations and for creating temporary bridge tooling during product launches. Rapid injection molding typically has a lead time of 2-3 weeks for initial parts, but with RapidDirect’s expedited services, you can receive parts in as little as five days.

Opting for injection molding over 3D printing or CNC machining is beneficial when your project demands strict material properties or specific mechanical requirements that other methods can’t achieve. RapidDirect excels in this area, offering high repeatability and near-final shapes with each prototype. Our expertise ensures that you receive reliable and precise prototypes, aiding in effective product development and testing.

Maximum Part Size: 1200×1000×500 mm

Standard Lead time: 2-3 weeks

Mold Cavity Tolerance: +/- 0.05 mm

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Rapid Sheet Metal Prototyping Service

Sheet metal fabrication is perfect for producing flat parts that need to be tested in their final metal form quickly. This method enables prototypes to be made within a week or less, offering a fast and efficient solution. It is also cost-effective, allowing the creation of multiple prototype designs simultaneously. While Aluminum 5052 is a common choice, we also offer a variety of other alloys, including steels, copper, and stainless steel.

Choosing RapidDirect for your sheet metal prototyping ensures you benefit from our extensive experience and streamlined processes. We provide a wide range of materials and guarantee high-quality rapid metal prototyping services that meet your project requirements accurately and promptly. With RapidDirect, you can expect reliable, precise, and swift delivery of your sheet metal prototypes, keeping your design process on schedule and within budget.

Cutting Feature: ± .00787” (0.2mm)

Bend Angle: ± 1.0°

Bend to edge: +/-0.010″(0.254mm)

Bend to hole: +/- 0.2 mm

Standard Lead time: 1-2 business days

General Tolerances: Metals : ISO 2768-c

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Rapid 3D Prototyping Service

3D printing stands out as the leading method for rapid prototyping due to its speed and cost-effectiveness. This technique enables the quick and economical creation of prototypes, often ready for dispatch within a day at minimal cost. The primary 3D printing methods for rapid prototyping include Selective Laser Sintering (SLS), Stereolithography (SLA), and Fused Deposition Modeling (FDM).

SLS is highly versatile, offering a balance of speed, mechanical functionality, detailed resolution, and affordability. SLA provides the finest surface finish and exceptional accuracy, making it perfect for creating clear parts with precise tolerances. FDM is ideal for producing larger parts from a variety of engineered thermoplastics such as ABS, PC, and ULTEM, capable of fabricating items up to 36” in size in a single piece.

Choosing RapidDirect for your 3D printing needs ensures you benefit from our expertise and advanced capabilities. We manufacture high-quality 3D printed parts that meet your specific project requirements. With RapidDirect, you receive reliable, precise, and fast prototyping solutions that help accelerate your product development process.

Max. Build Size: 1400x700x500mm

Standard Lead time: 4-6 days

Dimension Tolerance: ±0.2mm (For >100mm, apply 0.15%)

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Rapid Vacuum Casting Prototyping Service

Vacuum casting is a preferred prototyping technique for producing high-quality, detailed replicas quickly and cost-effectively. This method is especially advantageous when you need small to medium quantities of functional plastic parts with the quality of injection-molded products. It allows for the precise replication of details and textures, making it perfectly suited for test marketing, functional testing, and proof-of-concept demonstrations.

Choosing RapidDirect for vacuum casting means leveraging a streamlined process that ensures fast delivery and high fidelity in every prototype. Our rapid vacuum casting service offers a versatile range of materials and finishing options, accommodating diverse prototyping needs. This flexibility, coupled with our dedication to quality and speed, positions RapidDirect as a leader in delivering prototypes that meet exacting standards. With our expertise, you can accelerate your product development timeline while maintaining rigorous quality control.

Maximum Part Size: +/- 0.025 m

Standard Lead time: Up to 20 parts in 15 days or less

Tolerance: ±0.05 mm

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How to Choose
The Right Rapid Prototyping Technique

	Advantages	Disadvantages
Rapid CNC Machining	High precision and suitability for a variety of materials. Ideal for functional and durable parts.	Higher cost and longer lead times compared to some additive manufacturing processes.
Rapid Injection Molding	Excellent for high-volume production. Provides end-use, functional parts with fine details.	Upfront costs for molds are high, less economical for small quantities.
Rapid Sheet Metal Fabrcation	Good for durable prototypes, allows quick modifications. Suitable for both prototyping and production.	Limited complexity, not ideal for intricate designs requiring high detail.
Rapid 3D Printing	Fast and cost-effective. Capable of complex geometries that are not possible with other methods.	Material properties might not match those of traditionally manufactured parts. Resolution varies by technology.
Rapid Vacuum Casting	Suitable for producing small quantities of highly detailed replicas quickly and affordably.	Generally used for non-functional prototypes or visual models due to material properties.

Why
Choose Us

/01

High Quality
Parts

RapidDirect ensures top-notch prototype quality by using advanced materials and precision techniques, adhering to strict industry standards.

/02

Fast Lead
Time

Our efficient processes enable quick delivery of prototypes, significantly cutting development time and speeding up market entry.

/03

Engineering
Support

RapidDirect provides extensive engineering support, assisting with design optimization and technical challenges to improve prototype development.

Success Stories of Our Valued Customers

RapidDirect x 2024 Core77 Design Rewards Trophies

In 2024, Core77 partnered with RapidDirect to bring this visionary design to life, leveraging our end-to-end manufacturing expertise and intelligent platform.

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RapidDirect x VR Shoes: Innovation with Precision Prototyping

See how RapidDirect's vacuum casting & 3D printing enabled robust VR shoe prototypes, slashing development time and costs for immersive tech innovation.

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Case Study: RapidDirect Powers Arco Aria’s Tether Car Success

Thanks to RapidDirect, Arco successfully modified his tether car’s engine, including turning the crankshaft and designing a new intake system for improved efficiency.

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RapidDirect × Sylphaero: A Partnership for Sustainable Plasma Jet Engine

Sylphaero aims to revolutionize aviation with sustainable electric plasma jet engines, focusing on decarbonization. RapidDirect provides crucial precision machining support, highlighting the importance of innovation and strategic partnerships in the sector.

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RapidDirect x Rennteam Stuttgart: Innovation Collaboration of Racecar Engineering

RapidDirect proudly supports Rennteam Stuttgart by manufacturing 2 mainbar components and over 80 Aluminum inserts. Our precision engineering ensures they're ready to conquer the Formula Student competitions, giving the team a winning edge.

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Case Study: LURA’s Partnership with RapidDirect for Precision Rocket Engine Parts

LURA, the Leeds University Rocket Association, used RapidDirect's 5-axis CNC machining and turn-mill compounding techniques to create intricate engine parts essential for their victory in the National Race to Space Propulsion Competition.

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We Support
From Prototyping to Production

Rapid Prototypes

Rapid prototypes are produced quickly to enable immediate testing, feedback, and iteration, speeding up the development process.

Design & Engineering Validation

Prototyping services validate design and engineering specifications to ensure functionality and performance before mass production.

High Volume Production

Transitioning from prototype approval to high volume production is streamlined to maintain quality and meet production deadlines efficiently.

Prototyping
Resources

RapidDirect x Rennteam Stuttgart: Innovation Collaboration of Racecar Engineering

Dec 20, 2023

RapidDirect x Rennteam Stuttgart: Innovation Collaboration of Racecar Engineering

Dec 20, 2023

RapidDirect x Rennteam Stuttgart: Innovation Collaboration of Racecar Engineering

Dec 20, 2023

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Rapid Prototyping
with RapidDirect

What is
Rapid Prototyping