Rapid Prototyping Services for Precision Metal Components
Prototyping at Brunk is the phase between a finalized design and tooling with large scale production. The primary objective is to produce physical parts that are representative of what production will yield, so that form, fit, and function can be validated on parts made from the correct material and to the correct dimensional standard before hard tooling is built. This process equivalence is what separates production-intent prototyping from early-stage concept modeling, and it is the basis on which Brunk structures all prototype work.
Brunk’s prototyping capabilities include waterjet cutting, laser cutting, 3D printing, and in-house prototype tooling (single-hit tooling). Each method has a different appropriate application depending on the material, geometry, and quantity of prototypes desired. Brunk’s applications engineers will recommend the method that produces the most useful data for the program’s current needs, and in some cases a combination of methods is used across different features or components in the same assembly.
Production-Intent Prototyping for Regulated Industries
For programs in medical device or other regulated industries, prototyping decisions have downstream consequences that extend beyond form and fit. Parts produced by a process that differs from the intended production method may not generate valid data for biocompatibility testing, sterilization validation, or dimensional qualification under FDA or ISO 13485 requirements. Brunk’s approach to prototyping is structured around this reality. Where the target production process is progressive stamping, prototype parts are produced using methods that preserve the work-hardened material properties and surface conditions of the stamped part rather than substituting a machined or printed equivalent. This approach reduces the risk of having to repeat validation testing after production tooling is built.
Prototype runs at Brunk generate documented dimensional data, material certifications, and process parameter records that carry forward into the production quality plan. Because all prototyping is performed in-house using Brunk’s own equipment and quality systems, the process knowledge accumulated during prototyping stays with the program team through production.
Prototyping Methods at Brunk
Brunk offers four prototyping methods that cover the range of geometries and materials encountered in precision contract manufacturing programs. Each is described on its own page with detail on process parameters, suitable applications, and how it connects to the downstream production process.
From Prototyping to Production
Prototype programs at Brunk are structured to support a controlled transition into production. Dimensional measurements, material certifications, and process parameters documented during prototyping feed directly into the production quality plan, which reduces the validation burden when the program scales. Because tooling design, prototype production, and volume manufacturing all operate under Brunk’s quality management system, the documentation and process knowledge built during prototyping do not need to be reconstructed at the production stage.
