Rapid Prototyping Cost Overview

Rapid Prototypes are essential for product development, and offer tangible representations of concept. many engineers have a question How much does a prototype cost?

To ensure a successful project, it is needed to understand the cost factors associated with rapid prototyping so that you can make a reasonable budget at the beginning. In this article, we explain the costs for different ways of creating prototypes, such as CNC prototypes, 3D printing prototypes, and urethane casting prototypes.

How to calculate prototype cost?

Prototype cost consists of material cost, machining cost, labor cost, and surface finishing cost. material cost is calculated by part weight, machining cost, and labor cost calculated by hourly rate. so, this will link to the timing used for machining and labor operating which means the more complex the prototype, the longer the lead time will be taken, and then the cost of a prototype will be higher.

How Long Does It Take To Make A Prototype?

Generally, it will take less than 10 days to make a single plastic or metal prototype, this will depend on the complexity of the design. for example, for a plastic optic light guide in automotive lighting with an optics pillow on it, it will take at least 5 days due to small optics needing more time to make on the CNC machine.

How much does CNC machining Plastic Prototype Cost?

CNC machining prototype cost consists of material cost, machine cost, labor cost, and post-surface finishing cost. So to understand the CNC prototype cost, you need to understand how to calculate the cost of each factor as below.

Material Cost

Different materials vary in cost, Clear materials like Acrylic and polycarbonate are more expensive than ABS. Material cost significantly affects the cost of CNC prototypes.

Here is a data table showing the cost of major plastic sheets (30mm thickness) commonly used in CNC prototypes:

CNC Machine Hourly Rate

The CNC machine hourly rate is another important factor affecting the overall cost. Machine shops charge an hourly rate for utilizing their CNC machines, which can be different depending on the shop’s location, and machine types.

Complex geometries require longer machining time, which leads to a higher cost. Here is a table showing the estimated hourly rates of 3-axis, 4-axis, and 5-axis CNC machines:

Labor Hourly Rate

Labor costs are also a key factor affecting CNC prototype costs. Skilled technicians and operators are required to program and set up the CNC machines, as well as perform post-finishing and quality checks after CNC machining.

Labor cost is different in different countries, labor hourly rates for prototype manufacturing in China is significantly lower than in other countries.

Based on the costs of each factor listed above, Generally, The cost of CNC prototypes ranges from $100 to $1000. The cost could be higher if your design is complex and needs more time.

How much does 3d Printing Plastic Prototype Cost?

just like the CNC machining prototype cost calculation above, the cost factors of 3D printing prototypes are as below:

Material Cost

The 3D printing materials significantly impact the cost of 3D printing prototypes. it is the Main contributor to the total cost because the 3D printing machine is cheap and does not need much post-finishing work after the 3D printed prototype. Below is a table showing the cost of different 3D printing materials per gram (g).

3D Printing Machine Hourly Rate

The hourly rate of the 3D printing machine used for prototyping is usually not taken into account when calculating the 3D Printed prototype cost because the machine is relatively cheap.

Labor Cost

The labor cost for 3D printing prototypes also not be taken into account for the final 3D printed prototypes because not much post-processing worked need after 3D printing.

in short, Generally, A 3D printing prototype cost range from $10to $200. The cost could be higher if the size of your product is big.

How much does Urethane Casting Prototype Cost?

Urethane Casting Prototype Cost consist of Master Pattern Cost, Silicon Mold Cost, casting material cost, and labor cost.

Master Pattern Cost

The master pattern is used for creating the silicone mold. The cost of the master pattern depends on the manufacturing method, such as CNC machining or 3D printing, you can refer to the above information.

Casting Material Cost

Different urethane resins come with different properties such as rigidity, flexibility, clarity, and heat resistance which result in different resin costs. Here is a table showing the approximate cost of different casting materials used for urethane casting prototypes:

Silicon Mold Cost

The cost of making the silicone mold is a key factor for urethane casting prototype cost. it can be different depending on the size, complexity, and quantity of molds required. Below are some estimated costs for silicone molds:

Labor Cost

Labor costs involve the skilled technicians who handle the entire casting process, including preparing the master pattern, mixing and pouring the casting material, and demolding the final prototypes. this is the same with CNC machining prototypes.

In Summary, Generally, Urethane Casting Prototypes cost ranges from $10 to $100. the silicone mold cost can be amortized to the piece cost which means, the more prototypes you make, the lower the piece cost you can get.

Post Processing Cost

Polishing Labor Cost

Polishing is a common post-processing step to achieve a smooth and glossy surface finish for prototypes. For an optic clear prototype, it takes days to finish the polishing to get the high glossy surface. The cost of polishing labor will depend on the size and complexity of the parts. It is typically charged on an hourly basis with the time spent on manual polishing.

Fit And Assemble Labor Cost

Usually, the prototypes require assembly. The labor cost will depend on the time spent on assembly. If the assembly is complex, more time is needed to finish the job.

Surface Finishing Cost

Surface finishing is needed in the prototype manufacturing process to get the required appearance of the prototypes. different surface finishing will cost differently. Here is a table showing the estimated cost of different types of surface finishing for prototypes:

3 Tips To Reduce The Cost Of The Plastic Prototype

Use Less Expensive Materials

Choosing cost-effective materials can impact prototype costs much. Evaluate your project requirements and consider using less expensive materials that still meet your design and functional needs. For example, if your prototype doesn’t require high-performance properties, consider using standard plastic materials like ABS or PLA instead of more expensive engineering plastics.

Select A More Cost Effective Manufacturing Process

Select the best prototyping methods according to your project’s complexity and volume. For lower volume requirements, 3D printing, or urethane-casting might be more cost-effective compared to CNC machining.

Design Optimization

Simplifying the design can reduce material usage, machining time, and post-processing requirements. Eliminate unnecessary features and components that don’t contribute to the functionality of the prototype.

How To Start A Prototype Project?

To start a prototype project, you need to find a proper prototype manufacturer who can manage your products with experience. If you’re looking to lower your prototype cost while maintaining high-quality results, KUSLA’s Rapid prototyping service can provide the right solution for you. We offer a wide range of cost-effective prototype services with the support of our advanced technology and highly skilled team.

How much do the prototypes cost?

Thanks to the low labor cost in China and Fast working pace, partnering with KUSLA Prototype, you can significantly lower your prototype cost. Here are the cost range and average timelines for building prototypes depending on the types in KUSLA for single plastic prototypes from different machining methods.

Summary

The final cost of rapid prototyping depends on the machining process, material, part size, and structure. Anyway, A simple plastic prototype part can cost from $10 to $200, and a complex prototype assemblies project can cost from $1000 to $50000 and even more.