Why the material matters

A look-alike prototype shows the shape but behaves differently from the series product. Stiffness, creep, temperature behaviour, friction and the way a snap fit flexes: all of it depends on the material.

Validate on a non-representative prototype and problems surface only after the tooling investment. Modifying a mould costs many times more than an extra prototyping round.

That is why Exten produces prototypes in the intended production material wherever possible, for example machined from the same POM, ABS or aluminium that will later be moulded or cast. See also materials.

Before a mould investment

Validate the design functionally before committing thousands of euros to injection-moulding tooling.

With mechanical requirements

Testing strength, stiffness, wear or snap fits demands the real material.

For assembly validation

Fits, tolerances and inserts behave representatively in the final material.

For small pilot series

A small series in the final material can serve as a pilot run for field tests or certification programmes.

Limitations

Not every detail can be replicated one-to-one. A machined part has no flow lines or draft angles like a moulded part, and some process-specific properties only arise in series production. For each project we state what the prototype does and does not test representatively, so you know what you are validating.

Suitable techniques

CNC milling and turning are usually the first choice: almost any technical material can be machined from block or sheet, to close tolerances. Vacuum casting suits plastic parts with moulding-like properties; plastics machining covers sheet and block materials such as POM and PMMA.

The finish can be representative too: textures, coatings and galvanic layers such as chrome plating. So you test the product as it will reach the market.