RAPID PROTOTYPING AND R&D SUPPORT
Build, test and learn before committing to production
In-house 3D printing backed by extensive mechanical design and R&D experience.
Ekyos helps turn an uncertain idea, design problem or engineering question into something that can be handled, assembled, measured and tested. The aim is not to print for the sake of it. The aim is to learn what should happen next.
QUESTION
BUILD
Produce the simplest useful prototype.
TEST
Check fit, handling, assembly or function.
LEARN
Use the evidence to improve the design or process.
Prototypes should answer questions
A rapid prototype is useful when it reduces uncertainty. The required fidelity depends on the decision, so a rough development part may be more valuable than a polished model.
01
Concept and packaging models
Make size, shape, access and spatial relationships tangible before detail design is fixed.
02
Fit and assembly checks
Check interfaces, access, orientation and assembly sequence before committing to tooling or machined parts.
03
Development and test parts
Produce controlled prototypes for practical trials where the selected process and material are suitable for the intended test.
04
Jigs, fixtures and workshop aids
Develop simple tools that support repeatable inspection, positioning, handling, assembly or testing.
The useful output is the decision, not just the part
3D printing is one tool within an engineering development process. Sebastian brings extensive R&D and mechanical design experience to help decide what needs proving, what can be simplified and what evidence is required before the next commitment.
This may include reviewing load paths, interfaces, clearances, assembly, likely failure modes, manufacturability and the realism of the proposed test.
Typical support
- Clarify the engineering question before modelling
- Review, repair or develop suitable CAD geometry
- Select a proportionate prototype approach
- Plan what to inspect, measure or test
- Interpret results and identify the next iteration
- Prepare the design for another manufacturing route when appropriate
A practical development process
The process is deliberately simple. More documentation is added only when the risk, complexity or customer requirement justifies it.
01
Define the question
What must the prototype prove, reveal or help somebody decide?
02
Review the design
Check available CAD, interfaces, likely loads and any missing assumptions.
03
Plan the build
Agree the machine, material, orientation, finish and inspection appropriate to the purpose.
04
Make and test
Produce the prototype, inspect it and carry out the agreed practical checks.
05
Iterate or hand over
Record what was learned, modify the design or define the next manufacturing step.
Capability is confirmed for each project
Ekyos has in-house 3D-printing capability, but no machine or material is suitable for every requirement. Build volume, material behaviour, dimensional expectation, surface finish, inspection and delivery timing are reviewed before a quotation is accepted.
Where another process is more appropriate, Ekyos can identify that early rather than forcing the job through a convenient machine.
Important boundaries
- Prototype suitability does not prove production suitability
- No safety-critical or regulated end use is assumed
- Tolerance and finish are agreed, not implied
- Customer files remain subject to scope and ownership checks
- External manufacturing or specialist processes require separate agreement
Common questions
Do I need finished CAD?
No. A sketch, existing part, requirement or incomplete model may be enough to start the technical discussion.
Can Ekyos print my existing file?
Possibly. The geometry and intended use are reviewed first. A printable file is not automatically a sound prototype.
Can a prototype become a production part?
Sometimes, but that decision needs separate assessment of material, process control, loads, environment, life and compliance.
How should confidential files be sent?
Do not attach sensitive information to the initial enquiry. Ekyos will agree a suitable transfer route if the project is a fit.
What do you need the prototype to prove?
Describe the design problem, available information, intended test and required decision. Ekyos will confirm whether an in-house prototype or another engineering route is the sensible next step.