Mechanical, Ergonomic & Visual Design of New Products
Engineering Prototype Construction


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Design Innovation can provide you with engineering prototypes made by several methods. We can make machined working models incorporating repeatably flexible sections and precision snapfits, either from 3D CAD files or from 2D drawings. We can also have SLA (stereolithography) or other Rapid Prototype models made from a variety of materials, depending on the physical properties required. From any of these models, limited-use silicone molds can be made to provide cast urethane parts for detailed prototypes or even first production.
Machined Delrin Prototype    
Preamp and Delrin Model The preamp on the left is an injection molded production unit, and the preamp on the right is the original prototype that was constructed as a proof of concept. It was machined out of Delrin, and provided all the mechanical function of the production units, including repeatably flexible sections and snapfits. After CAD files were generated from this initial design, SLA models were made to further validate it. The CAD files were then sent overseas for moldmaking and manufacturing. The production unit has been selling worldwide for the last few years.
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Stereolithography and Urethane Prototypes
SLA Model of PreampPro-EQ Preamp
The model on the left is made with the SLA (stereolithography) process. This is a very economical method for quickly making solid models from 3D CAD files. The physical properties are generally inferior to machined models, but in many cases working prototypes can be built from them, as was done in this project. In the model on the right, a set of the SLA parts were used to make silicone molds from which urethane parts were cast, detailed and then assembled, allowing realistic display and demonstration at a trade show while the production molds were under construction.
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Stereolithography Prototype
Platinum and SLA
The SLA shown here models the top of the preamp. Like the unit above, full SLA sets were used to prove out the design, provide fully functioning prototypes, and to make molds for cast urethane parts.
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