07/05/2025

3D Printing Materials for Rapid Prototyping

Choosing the right prototyping materials can speed up development, reduce costs, and get your product to market faster.

By Protolabs

Rapid prototyping lets you move from CAD to part in just days. But not all prototypes need the same material. Some are built for show. Others need to hold up to real-world testing. Here's how to pick the right 3D printing material for the job. 


Considerations for material selection in rapid prototyping 

When choosing a material for rapid prototyping, it all comes down to what your prototype needs to do. Is it just for checking fit and form? Or does it need to handle stress, bending, or even high heat? Some prototypes are built for looks, others for performance, and your material choice should match the job. 

Form and fit 

If you’re checking dimensions, tolerances, or how parts connect, you don’t need a high-end material. What matters is accuracy and speed. These prototypes are often handled, assembled, and maybe passed around the office—but they’re not expected to perform under load. 

Good options 

  • PA 12 (SLS or MJF): Durable, flexible enough for clips and latches, and doesn’t need support structures. 
  • ABS or PLA (FDM): Quick, inexpensive, good enough for basic form testing. 
  • SLA resins: Great for parts that need crisp details and a smooth surface. 

Functional testing 

This is where things get more demanding. If your prototype needs to move, bend, hold weight, or resist wear, choose a material that mimics the real-world conditions your final part will face. 

Good options 

  • PA 12 Glass‑Filled (SLS/MJF): More rigid and stronger than standard nylon—great for load‑bearing parts. 
  • Carbon RPU 70 or EPU 40 (DLS): Tough, production-grade materials ideal for impact or flex testing. 
  • 316L Stainless Steel (DMLS): Fully functional metal parts for critical applications.

Surface finish and appearance 

If your prototype needs to look the part—not just act the part—surface quality counts. Smooth finishes, fine details, and even transparency can make a big difference, especially for presentation models, ergonomic studies, or anything that needs stakeholder sign-off. 

Good options 

  • SLA resins: Offer high detail and smooth surface finishes, with options for clear or opaque materials depending on your application. 
  • PolyJet: Offers multi-colour, multi-material options with ultra-fine resolution. 

Speed and cost 

When you're in early-stage iteration mode, fast and cheap is usually the winning combo. These materials are good for rough concepts or design tweaks before you move on to functional tests. 

Good options 

  • PLA or ABS (FDM): Inexpensive and widely available—perfect for same-day concept validation. 
  • PA 12 (MJF): Popular choice for batching multiple parts with consistent strength and fast turnaround. 


Examples of 3D printing materials for rapid prototyping  

What makes a material good for rapid prototyping? Speed is a major factor—some materials print faster than others due to lower curing times, simpler geometries, or compatibility with high-throughput technologies like MJF or FDM. Thermoplastics like PLA and PA 12 are particularly fast and efficient to print, making them ideal for early-stage iterations. 

But speed isn’t everything. Choosing the right prototyping material also depends on what you're trying to learn. Early concepts often call for fast, affordable prints to test basic form and fit. As your design matures, you may need tougher or more precise materials to validate function, aesthetics, or mechanical performance. 

The best choice is just the one that supports your next design decision. 

Rapid Prototyping Material Quick Guide  

Prototype goal 

Material 

Why it works 

Fit check 

PA 12 (SLS / MJF), ABS (FDM) 

Accurate, durable, and quick to produce 

Visual model 

Smooth finish, fine detail, optional translucency 

Snap-fit assembly 

PA 12, PA 12 GF (SLS/MJF) 

Strong, flexible, and good for functional features 

Heat resistance 

Accura 5530 (SLA), Aluminium (DMLS) 

Withstands higher temps without warping 

Flexible part 

EPU 40 (DLS), 3D‑printed silicone (PolyJet) 

Mimics rubber—great for wearables or seals 

Metal component 

Titanium or Stainless Steel (DMLS) 

High strength, corrosion resistance 

Budget iteration 

PLA, ABS (FDM) 

Low cost, fast print, ideal for rough concepts 


Applications and uses 

Prototyping materials aren’t one-size-fits-all. Industries often favour different materials based on typical use cases and part performance requirements. 

  • Automotive teams often use PA 12, Carbon RPU 70, or ABS for quick-fit checks, snap-fit features, or under-the-hood housings. These materials are tough enough to test form and function at once. 
  • Aerospace applications rely on lightweight, high-performance options like PA 12 GF, titanium, or aluminium for brackets, ducting, and housings that need to withstand demanding conditions.  
  • Medical and dental designers use SLA resins, 3D printed silicone, and EPU 40 to create precise anatomical models, surgical tools, and comfortable wearable parts.  
  • Consumer product developers often opt for SLA resin, PA 12, or PolyJet to produce visual models, device enclosures, or proof-of-concept units with sleek finishes. 
  • Industrial equipment requires durable, repeatable materials that can endure harsh conditions and maintain consistent performance. This often includes high-strength polymers and production-grade metals for use in load-bearing or extreme temperature applications.  

How materials help in real-world prototyping 

  • ForgTin, a medical device company, used DMLS with 316L Stainless Steel to create a durable and compact tinnitus relief device with fine detail and strength. 
  • General Drones used MJF and SLS with PA 12 to rapidly 3D print lightweight, precise, multi-geometry parts for rescue drones that respond to emergencies at sea. 
  • Downhole Emerging Technologies, a geothermal energy company, used DMLS with Inconel 718, 316L Stainless Steel, and 17-4 Stainless Steel to quickly produce high-performance equipment that wouldn’t melt or corrode in extremely high temperatures. 

Strengths and limitations of prototyping materials 

Each material has its upsides—and trade-offs. Here's what to expect: 

Material 

Technology 

Strengths 

Limitations 

PA 12 

SLS / MJF 

Durable, accurate, versatile 

Grainy surface, limited colour options 

SLA resins 

SLA 

High detail, smooth surface 

Brittle, not ideal for mechanical loads 

ABS/PLA 

FDM 

Fast, cheap, accessible 

Lower resolution, rougher finish 

Carbon RPU 70 / EPU 40 

DLS 

Production-grade strength or flexibility 

Higher cost, longer lead times 

PolyJet 

Soft, flexible, biocompatible 

Limited colour and shape complexity 

DMLS 

Strong, functional, great for heat 

Expensive, requires post-processing 


Ready to scale? Selecting materials for production 

Prototyping is just the first step. Once your design is validated, you might continue with 3D printing for production—or switch to another manufacturing method. The best approach depends on your part requirements, budget, and volume. 

Some 3D printing materials are engineered for durability and end-use performance. Carbon RPU 70 and EPU 40, for example, are strong and flexible enough for real-world applications like consumer products, wearables, and flexible components.  

These materials are produced with Carbon DLS, a production-grade 3D printing technology that offers smooth finishes and consistent quality—without the need for tooling. It’s ideal for bridge production: when you need a few thousand parts quickly, with end-use quality, but aren't ready to invest in injection moulding. Carbon DLS delivers the flexibility to iterate, scale, and go to market faster. 


Frequently asked questions about 3D printing materials 

Can I prototype and produce with the same material?

Yes, if the material meets your performance and cost needs. Carbon DLS and PA 12 are great for both. 

What’s the cheapest material for early-stage prototyping?

FDM materials like PLA or ABS are the most affordable. 

Which material has the best surface finish?

SLA resins and PolyJet materials offer the smoothest finishes. 

Do I need to consider colour at the prototyping stage?

Not always, unless colour impacts part identification, appearance, or function. 


Where to learn more about 3D printing 

Want to go deeper into material properties, design tips, and process comparisons? Explore these Protolabs resources: 


Get a quote 

Let’s fast-track your prototype. Upload your CAD model for a free, instant quote. 

Working with specialised or non-standard materials? Email our team at networksales@protolabs.com—we love a challenge. 

Tagged: 3D Printing