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Rapid Extrusion Prototyping - Fast, Easy, Inexpensive

The Problem: Traditional Manufacturing

Prototyping extrusions can be difficult and costly for a lot of reasons. Many engineers have traditionally approached the prototyping of these two products through two means: machining billet into a close net shape or producing tooling and extruding the prototypes. These processes have large drawbacks:

Extrusion Machining Issues : 

Machined extrusion prototypes waste a lot material and machining/programming time making them very costly in low volumes.

Machining has difficulty milling certain features common to extrusions like thin walls, deep draws without draft and sharp angles.

Machining lends itself better to repetitive production runs of parts, making iterative prototyping very time consuming. Getting iterations of machined parts will generally either take 3 to 6 weeks or rack up heavy expedite fees.

Extrusion Tooling Issues:

Creating tooling for exact extrusions generally takes up to 12 weeks to produce a run of prototypes.

Production tooling is extremely expensive for low-volume prototype runs, costing from thousands to tens of thousands of dollars for a tool that may only be used once.

10" tall aluminum 3D printed extrusion prototype with impossible to machine features and a deep draw. It would be very time consuming and expensive to make extrusion tooling for this part.

10" tall aluminum 3D printed extrusion prototype with impossible to machine features and a deep draw. It would be very time consuming and expensive to make extrusion tooling for this part.

The Solution: Additive Manufacturing/3D Printing

Prototyping your extrusions with additive manufacturing alleviates all of the issues presented by traditional processes.

3D Printed Extrusion Solutions:

3D printed parts require no tooling at all. Only pay per part that you make.

Lead times can be as little as a business day for plastic and a week for metal extrusion prototypes.

3D printed prototypes can do all the features with which machining struggles, walls as thin as 0.020", zero draft draws as deep as 12 - 14" (or longer), and sharp angles with no radii. 

RapidMade offers a wide range of material options from extremely fast, affordable and recyclable ABS plastic to metals like aluminum, stainless steel and titanium.

A small batch run of 30 3D printed aluminum extrusions produced within a couple days.

A small batch run of 30 3D printed aluminum extrusions produced within a couple days.