3D Printing
3D Printing for Precision Manufacturing Prototypes
3D printing, or additive manufacturing, builds parts layer by layer from a digital file. Within a precision contract manufacturing program, 3D printing occupies a specific and limited role: it is the right tool for evaluating geometry and assembly interfaces before production-intent material parts are available, and for producing fixtures and gauging aids that support downstream prototype and production operations. It is not a substitute for production-intent prototyping in cases where material properties, surface condition, or dimensional accuracy must represent what production will yield.
Understanding where 3D printing fits and where it does not is a practical consideration in program planning. Using printed parts in place of production-intent metal prototypes for functional or regulatory testing can generate data that does not transfer to the production design, which creates rework and schedule risk later in the program.
Where 3D Printing Is Used at Brunk
Brunk uses 3D printing at two stages of a program. Early in development, printed parts are used for geometric validation: verifying that the designed profile fits the intended assembly envelope, that mating interfaces align correctly, and that no obvious design errors exist before investment in metal prototype parts is made. This kind of check can be done quickly and inexpensively with printed geometry and frequently surfaces issues that would otherwise not be found until a metal prototype is in hand.
3D printing is also used to produce fixtures, nest plates, and gauging aids that support prototype and production operations. Custom fixtures produced by additive manufacturing are faster and less expensive to produce than machined aluminum or steel fixtures, and for low-load applications they perform adequately. Where fixturing must withstand production forces or maintain tight dimensional stability over time, machined fixtures are used instead.
Limitations Relevant to Regulated Programs
For programs subject to FDA oversight or ISO 13485 requirements, the limitations of 3D printed prototypes are particularly relevant. Printed parts in polymer or metal powder materials do not replicate the microstructure, mechanical properties, or surface condition of wrought metal parts produced by stamping or machining. This means that dimensional, functional, or biocompatibility data collected on printed prototypes generally cannot be used to support design verification or regulatory submissions for the production design. Brunk communicates this clearly during program planning to ensure that the prototyping method selected for each test objective is appropriate for the intended use of the data.
Discuss Your Prototyping Requirements
Brunk’s applications engineers can help determine where 3D printing fits within your program’s prototyping strategy and when production-intent metal prototypes are required.
Frequently Asked Questions
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