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Mechanical, Ergonomic & Visual Design of New Products
Product Design and Prototyping
Fabrication of prototypes and short-run production
 
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Design Innovation can provide you with engineering prototypes made by any of the standard manufacturing processes, plus rapid prototyping techniques including stereolithography, 3D printing, fused deposition modeling and selective laser sintering. We can also make machined working models incorporating repeatably flexible sections and precision snapfits, either from 3D CAD files or from 2D drawings. While not illustrated in the photos below, we've had excellent prototype success with fused deposition modeling, which can produce parts with physical properties close to those of injection molded parts.

We have ongoing business relationships with rapid prototype service providers who can generally ship prototypes in under 48 hours. From any of these rapid prototype models, limited-use silicone molds can be made to provide cast urethane parts for detailed prototypes or even first production. We have a network of manufacturers with a proven history of delivering high quality, cost-effective parts. Assembly of prototypes and short-run production is performed by Design Innovation to strict quality standards. We are able to make prototype units and trade show models that look and feel like actual production units.

 
Machined prototype and injection molded production unit
Machined Delrin Prototype
- On the left is a production unit made of injection molded parts, and 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, stereolithography models were made to further validate it. The CAD files were then sent overseas for moldmaking and manufacturing. The mechanical features proved out in this prototype and incorporated into the product were then patented. The product has now been selling for about 10 years.
SLA prototypeCast Urethane prototype finished and paintedProduction units
Stereolithography and Urethane Prototypes - The model on the left is made with the SLA (stereolithography) process, which was very economical for quickly validating the 3D CAD files. The physical properties of a rapid prototype 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 center model, 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. The image on the right shows the production unit.
SLA model and final product
Stereolithography Prototype - The SLA (stereolithography) model shown to the left models the top section of the product. Full SLA sets were used to prove out the design, provide fully functioning prototypes, and to make molds for cast urethane parts while the production molds were under construction.
 
 
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