What's the right 3D printer for prototyping? Comparing 3D printing ...

14 Jul.,2025

 

What's the right 3D printer for prototyping? Comparing 3D printing ...

Since the invention of 3D printing in the s, the technology has developed into a robust manufacturing solution for simple and more demanding prototyping as well as more complex, industrial applications. 

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Engineers, designers, startups and established businesses can use 3D printing to work through their prototype development cycle. From basic look-and-feel models to bespoke custom parts for R&D or later-stage product testing, custom tooling and even end-use parts or large assemblies, 3D printing offers a variety of solutions. 

Today, we offer a wide range of 3D printing technologies for prototyping, from simpler processes like FDM (fused deposition modeling) using filament-based materials, to more complex ones like MJF (HP's Multi-Jet Fusion), which uses powder-based materials that are optimal for inserts, threads and painted surfaces. 

Let’s break down the 3D printing technologies available through our manufacturing network.

How do you select the best 3D printing process for prototyping?

Depending on your product application, there are several factors to consider when identifying the best 3D printing technology and process for your prototyping needs. These include your intent for the prototype (visual, functional, testing, high-volume or end-use) and your priorities and budget for the specific stage of development. 

It’s essential to determine early in the process whether functionality or cosmetic appearance is your first priority. This will help you select the right 3D printing process. As well, when more than one process can produce prototypes in similar materials, choosing becomes a cost versus properties comparison. 

Here are a few more general rules of thumb we use at Protolabs Network.

What are the key manufacturing criteria for your prototype? Dimensional accuracy, build size & support structures

It’s important to have an overview of the fundamental mechanics of each 3D printing process to fully understand the key benefits and limitations that will sway which matches your application. 

Let’s break down key criteria to cover when prototyping with 3D printing.

Dimensional Accuracy is connected to the level of detail each process can achieve and the build quality of each 3D printer. Processes that offer higher accuracy can usually create parts with finer features. Industrial-grade machines have higher accuracy and repeatability than desktop printers. Layer height (mostly relevant in FDM) impacts dimensional accuracy.

If you’re designing a prototyping part that will come into contact with other components, it’s critical that you define the necessary tolerances. As selecting a process with higher dimensional accuracy may increase your costs, you can also finish features with critical dimensions or small details after 3D printing (for example, by drilling holes or tapping threads).

Build Size determines the maximum dimensions of a part that a 3D printer can produce. For components that exceed the typical build size, consider migrating to an alternative technology or splitting the part into multiple components that can be assembled later.

Support structures determine the level of design freedom and affect how much post-processing to expect. Processes that require no support, like SLS or industrial FDM using Ultem, have fewer limitations and can produce free-form structures with greater ease.

Dimensional accuracy Typical build size Support FDM Prototyping: ± 0.5% (lower limit ± 0.5 mm) Industrial: ± 0.15% (lower limit ± 0.2 mm) 200 x 200 x 200 mm for desktop printers. Up to 900 x 600 x 900 mm for industrial printers Not always required (dissolvable available) SLA Prototyping: ± 0.5% (lower limit: ± 0.10 mm) Industrial: ± 0.15% (lower limit ± 0.05 mm) 145 x 145 x 175 mm for desktop. Up to x 750 x 500 mm for industrial printers Always required SLS/MJF ± 0.3% (lower limit: ± 0.3 mm) 300 x 300 x 300 mm (up to 750 x 550 x 550 mm) Not required

Another important aspect to consider when choosing a technology is the impact of layer height.

Due to the additive nature of 3D printing, layer height determines the smoothness of the as-printed surface and the minimum feature size a printer can produce (in the z-direction). Using a smaller layer height also makes the stair stepping effect less prominent and helps produce more accurate curved surfaces.

Typical layer thickness FDM 50 - 400 μm (most common: 200 μm) SLA/DLP 25 - 100 μm (most common: 50 μm) SLS 80 - 120 μm (most common: 100 μm)

3D printing for basic prototyping - manufacturing with FDM

If you’re looking to build a basic prototype on a budget - to visualize a part or design, check the look and feel, and have a rough idea of form, fit and function - FDM may be the best 3D printing option.

It’s important to remember that FDM uses filament-based thermoplastics. As such, parameters like infill and layer resolution will impact the accuracy and cost of your custom parts. The more infill you have, the more material you will need, raising the cost. 

As an extrusion-based printing method, FDM comes with its own design limitations and requires support structures in many instances. FDM machines can only make one part at a time, so if you have higher volumes of parts, then SLS and MJF may be more suitable. These technologies are suitable for volume prototyping as they can print multiple parts at the same time. 

3D printing for complex prototyping - manufacturing with SLA, SLS & MJF

If you aim to build more complex, highly accurate prototypes to test form, fit and function (or want to test parts for durability and strength), you will get the most out of SLA, SLS and MJF. For more complex prototyping, SLA, SLS and MJF are more efficient and easier to scale, and in many cases, the most cost-effective option, especially for the part quality you get. 

In terms of the materials these processes use, SLA uses liquid photopolymer resins and SLS and MJF use powder materials, so there’s nothing to remove after printing. SLA does use support structures, so if you’re printing intricate or detailed features, you’ll want to factor in removal time. 

Post-processing time is important to consider, especially when prototyping at higher volumes. With SLA, time is required to cure liquid resin, and ensure parts dry properly (referring back to the extra time needed to remove supports) 

 In contrast, SLS and MJF powder materials require time to cool and need to be able to be cleaned easily. Intricate or detailed features could result in cracked, blocked or filled internal holes/channels that can’t be cleaned. Designs should allow for cleaning, powder removal and sufficient cooling to ensure highly accurate prototypes.

Looking for a specific material or a technology unavailable on the platform? Get in touch with your sales or account manager.

What materials do 3D printers use?

Depending on the 3D printing technology you are using, materials usually come in filament, powder or resin form. The two main 3D printing material groups are polymers (plastics) and metals, while other materials such as ceramics (one of the newest materials to be used in 3D printing) or composites (perfect for strong, lightweight parts) are also available.

Polymers can be broken down further into thermoplastics and thermosets. The main difference between these two designations is how they behave when heated. When you heat thermosets, the material gets stronger, but can’t be remolded or heated after the initial forming. In contrast, you can reheat, remold and cool thermoplastics as necessary without leading to any chemical changes. 

Different technologies are built to print with certain materials more optimally than others, with the level of accuracy and material cost becoming mitigating factors.

What are thermoplastics and thermosets?

Thermoplastics are the most commonly used type of plastic. The main feature that differentiates them from thermosets is that they can go through numerous cycles of melting and solidifying. This means that you can reverse the process of heating and forming thermoplastics into the desired shape. 

As no chemical bonding takes place when you heat and form thermoplastics, you can recycle or melt and reuse them. One way to think about thermoplastics is to liken them to butter. You can repeatedly melt and resolidify butter, and with each melting cycle, its properties only change slightly. 

Thermoplastics have good mechanical properties and high impact, abrasion and chemical resistance. They can also be filled with carbon, glass or other additives to enhance their physical properties. Engineering thermoplastics, such as Nylon, PEI and ASA, are widely used to produce end-use parts for industrial applications.

Overall, thermoplastics are best suited for manufacturing functional prototypes and some end-use parts. It’s important to note that thermoplastic products are not suitable for load-bearing applications. 

Typical 3D printing thermoplastics SLS, MJF Nylon, TPU FDM PLA, ABS, PETG, Nylon, PEI (ULTEM), ASA, TPU

Thermosets (also known as thermosetting polymers or plastics), in contrast to thermoplastics, remain in a solid state after a single round of curing. They are better suited for applications where aesthetics are important, as they can produce parts with smooth surfaces (similar to what injection molding produces) and fine details.

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Generally, they have high stiffness but are more brittle than thermoplastics, so they are not suitable for functional applications. Specialty resins are available, that are designed for engineering applications (mimicking the properties of ABS and PP) or dental inserts and implants.

Common thermosets include phenolic, epoxy, silicon and polyurethane, which provide various benefits for production. Epoxies, for example, are tough, resistant to a wide range of chemicals and highly elastic.

Typical 3D printing thermosets (resins) SLA Standard resin, Tough resin (ABS-like), Durable resin (PP-like), Clear resin, Dental resin

10 Tips to Reduce the Costs and Lead Time of Rapid Prototyping ...

Rapid prototyping helps companies turn ideas into realistic proofs of concept, advances these concepts to high-fidelity prototypes that look and work like final products, and guides products through a series of validation stages toward mass production.

Engineers and designers have been creating hardware prototypes for decades, but the tools, materials, and methods used to create those prototypes have evolved tremendously. With rapid prototyping tools like 3D printers, product development teams can create prototypes directly from CAD data, and quickly execute rounds of design revisions based on real-world testing and feedback at a substantially lower cost than ever before.

Prototyping with 3D printers, however, can be quite different than with working with other traditional tools or outsourcing to machine shops and service providers. Cost factors, efficiencies, and design rules often don’t directly translate.

In this guide, we collected ten insights to help you optimize your 3D printing rapid prototyping workflow to be as cost and time efficient as possible, from choosing a technology to practical design tips.

1. Prototype In-House

For any business involved in prototyping, one of the first questions that comes up is whether to order prototypes from service bureaus and machines shops or to purchase equipment to prototype in-house.

Rapid prototyping stops being rapid when an outsourced part takes multiple days or even weeks to arrive. Outsourcing can quickly become expensive when a project requires dozens or more iterations. On the other hand, purchasing a variety of machinery to produce all the different parts in a single product often requires substantial investment, a dedicated location, and expertise to operate.

The answer is not always clear-cut, but the best practice for most companies is to bring the most frequently used prototyping tools in-house and outsource larger parts, and parts that require non-standard materials or complex machinery.

Smaller desktop or benchtop 3D printers can cover many of the prototyping needs for most companies. They’re fast, easy to use, can operate in an office environment, and require minimal training. Depending on the number of parts and printing volume, investment in a desktop 3D printer can break even within months and save weeks or months of lead time over the course of development.

Curious how 3D printing in-house compares to outsourcing or other prototyping or production methods for your application? Use our interactive tool to calculate return on investment and time savings with 3D printing.

2. Choose the Right Technology and Machinery

To find the right prototyping materials and equipment, first, consider what you need from your prototypes. Do you need prototypes for visual demonstration only or for testing the mechanical attributes of your product?

Understanding these needs will help you choose the right technology. For example, for basic concept models the only requirement could simply be speed—finish and details may not matter. Looks-like prototypes, however, may require technologies and materials designed for fine details and high-quality surface finishes, while functional prototypes might need to withstand mechanical stress or have specific properties, such as optical transparency.

Desktop 3D printers offer solutions for a wide variety of applications and can produce parts in materials with varied mechanical properties.

Compare the three most established 3D printing technologies for plastics today: fused deposition modeling (FDM), stereolithography (SLA), and selective laser sintering (SLS).

3. Automate Post-Processing

Post-processing is an often overlooked, but potentially time-consuming aspect of prototyping with 3D printing. Some technologies require less post-processing than others, but all 3D printed parts require a certain degree of post-processing.

Some aspects of post-processing can be automated to reduce labor time and costs. One example of an automated system is the Form Wash and Form Cure for Form 2 3D printers that simplify the cleaning and post-curing of stereolithography (SLA) parts.

4. Assemble Large Parts From Multiple Prints

3D printing large parts can be a costly and lengthy process, often requiring outsourcing parts to service providers with large industrial printers.

But, just as assemblies consist of many individual building blocks, splitting a model into smaller parts is a great solution to creating objects larger than what fits into the build volume of a 3D printer. You can add features to your design that will allow the prints to align themselves, or simply split the parts with straight cuts, requiring you to align them during the fastening process.

When selecting a bonding method, your primary consideration should be the strength of the bonded joints, which is dependent on the ultimate use case of the parts:

  • Chemical fastening: Use a bonding agent for art, scale models, and complex shapes that are not meant for functional use and to sustain impact.
  • Mechanical fastening: Add screw thread or pockets to functional engineering parts that require a robust mechanical connection or if you need to repeatedly attach and detach components.

5. Make Parts Hollow

By default, most 3D printers create fully dense parts. When you’re not printing functional parts that require a certain strength, hollowing out large and bulky designs can be a great way to save a considerable amount of material and printing time.

Learn how to use Formlabs print preparation software, PreForm, and Meshmixer’s (free) hollowing tool to hollow and prepare your model for printing in three simple steps.

6. Adjust Layer Height

Adjusting the layer height is a great way to reduce printing time. On SLA systems, for example, the difference between parts printed with 50 and 100 micron layers is often barely noticeable, but reduces printing time by 50%.

7. Optimize Schedule

There are a few methods for optimizing your printing schedule to get the highest throughput possible, printing close to 24 hours a day.

Best practices for optimizing schedule include:

  • Batch multiple parts into one build.
  • Print small, shorter runs during the day and large builds overnight.
  • Use multiple printers to distribute the workload and increase same-day throughput.
  • Use Dashboard to receive alerts when a print finishes and to manage and watch multiple printers remotely.

8. Reduce or Eliminate Support Structures

A poorly oriented part can result in excessive support structures. Excessive supports use more material, increase printing time, and require more post-processing time. Depending on your design, a part can often be printed with limited or without any support structures. Most print preparation software tools allow you to experiment with different part orientations and check how different setups affect overall print time and material usage before printing.

Some technologies might also be better suited to your designs than others. FDM printers often require excessive support structures for designs with complex shapes, angles, and overhangs. Support structures on SLA printers are easy to break away and support requirements can be reduced through smart software. SLS machines do not need support structures at all, as the powder acts as a support for the parts while printing.

9. Optimize the Design

While 3D printers offer a high degree of design freedom, a bit of time spent on optimizing part geometries goes a long way to ensure efficient printing of high-quality parts. When designing a part for 3D printing, make sure to follow design guidelines for the specific technology or printer.

Common optimizations include:

  • Maintaining wall thicknesses at or above minimum specifications.
  • Eliminating or supporting angled walls and steep overhangs.
  • Adding drain holes for hollow designs.
  • Consider using lattice structures to achieve an ideal balance between part strength, material usage, and print speed.

10. Prevent Failures

Failed parts and broken machinery wastes expensive engineering time and can set development cycles back by days or even weeks.

Fortunately, 3D printers have developed tremendously since the first desktop printers entered the market ten years ago and professional 3D printers today are tools that companies can rely on.

As a rule of thumb, you can reduce failures to statistical insignificance by following some simple rules:

  • Work with reliable machines and companies that provide training and technical support.
  • Keep your machine and workspace clean.
  • Take the time to set up your prints properly.
  • Print only with reliable, tested materials.
  • Check the expiration date of materials before printing.
  • Carry out regular service and maintenance as specified by the manufacturer.

Get Started With Prototyping In-House

Add 3D printing to your toolset and create precision prototypes in-house for a fraction of the cost and lead time of traditional tools or outsourced solutions.

See the quality firsthand by requesting a complimentary sample part printed on the Form 2 SLA 3D printer.

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