Rapid Prototyping Services

Bring your ideas to life with the power of our advanced technology and on-demand services. With rapid prototyping, get your preliminary product and evaluate the product development process. At Kemal, rapid prototyping processes reply on.

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Our Rapid Prototyping Capabilities

It is a unique process of creating a model or prototype with computer design to evaluate the product development. With Kemal, you can get superior quality error-free prototypes crafted with advanced technology and expertise. As a leading service provider, we prioritize functionality and speed to ensure you make an informed decision. We provide a wide range of options, consultation, and post-production services for a seamless customer experience throughout the prototyping process.

Get CNC machining with the latest computer-controlled equipment and precise design. Our team designed complex prototype parts within a few days with rigorous quality measures.

Custom engineering and manufacturing services from prototypes to on demand production of sheet metal parts. Low-cost sheet metal fabrication solution for you.

We create 3D plastic and metal prototype models of designs with specialized 3D printers under strict quality control. Kemal aims to manufacture high-quality, affordable three-dimensional products with the finest material.

Reliable vacuum casting service for prototypes and low-volume production parts at competitive pricing. Highly detailed elastomer parts with excellent quality and faster turnarounds.

Why Choose Us for Rapid Prototyping Services

At Kemal, we offer exceptional quality customized rapid prototyping of various parts. Whether you are looking for CNC machining, 3D Printing, or die-casting prototyping, we ensure the prototype parts are made with the best quality material under expert surveillance.

No MOQ

We offer no minimum order quantity (MOQ) policy to fulfill customers’ demands from prototyping to low-volume production. With the fastest turnaround, we ensure you get your prototypes cheaply.

Consistent High Quality

With quality control certifications, we follow a rigorous inspection process to ensure the products are manufactured with consistent industrial quality and precision. We perform dimensional verification to ensure error-free production.

Strong Manufacturing Capabilities

Kemal is a one-stop solution with strong manufacturing capabilities and quality manufacturing processes. From prototyping your designs to production and final assembly, Kemal is a one-stop solution for all manufacturing needs.

Fast Lead Time

To meet the on-demand production, we provide the fastest lead time of within 7 days with production specialties, such as advanced equipment, qualified technicians, and tracked development process.

Warranty & After-Sales

We offer reliable warranty services to ensure you are satisfied with the quality and functionality of delivered products. Moreover, with one-on-one assistance, we provide after-sales services for product troubleshooting and improvements.

24/7 Engineering Support

If you need assistance choosing materials, surface finishes, and design optimization, Kemal is your top choice. We provide 24/7 engineering support to ensure you select the proper tooling and material for your production.

Our Rapid Prototyping Processes

From quotation to final production, acknowledge the seamless order process at Kemal. Our qualified team ensures you get your plastic molded parts within the provided lead times.

Rapid Prototyping Services

Upload a CAD File

You can send us your design details and specification via the instant quotation platform. Our team will get back to you with the necessary information and cost estimation after review.

Rapid Prototyping Services

Get Quote with DFM

After reviewing your design details, our experts start with a detailed design for manufacturability (DFM) report to help you make an informed decision with high-quality and cost-efficient production.

Rapid Prototyping Services

Manufacturing Begins

Once you review your quote and place your order, we'll start the manufacturing process. We also offer finishing options.

Rapid Prototyping Services

Parts are Shipped!

Our digital manufacturing process allows us to produce parts in as fast as 10 day.

Rapid Prototyping Materials :60 Materials

We source rapid prototyping of more than 60 plastic and metal materials.

Aluminum

Aluminum

Aluminum is famous for producing quick and accurate rapid prototypes due to its high strength. It is a reliable option for CNC machining, and casting prototyping.

Copper

Copper

Copper is a profound prototyping material used to manufacture heat and corrosion-resistant parts. It can be formed or machined into different complex shapes due to its flexible nature.

Brass

Brass

Brass is well-known for machining compatibility and durable performance. It can withstand chemical damage and climate stress. With exceptional electricity conductivity, it is widely utilized in electronic and automotive parts manufacturing.

Stainless Steel

Stainless Steel

Stainless steel is corrosion-free and highly resistant to making a durable, high-strength prototype. It is convenient for machining, welding, surface polishing, etc., to meet your demands.

Types of Rapid Prototype

From 1995, we have produced prototypes for various industries including medical, automotives, aerospace, construction, and other industries.

Faster parts through Kemal Manufacturer

Get your parts CNC machined in 5 days.

From Rapid Prototyping to Production

Rapid Prototyping

Swift Prototyping With our cutting-edge instant quotation platform and robust manufacturing capabilities, we are able to deliver outstanding prototypes in record time. This allows you to quickly test and validate your prototype parts, accelerating the time to market.

Bridge Production

Bridging the Gap We understand the importance of bridging the gap between the design phase and the actual launch of your product. Our highly skilled engineering team is here to provide invaluable design recommendations to optimize your production parts, ensuring practical solutions that meet your specific requirements.

On-Demand Production

On-Demand Manufacturing Our comprehensive on-demand production service guarantees unrivaled precision and quality in all our products. Leveraging our advanced manufacturing process, we are able to achieve efficient production rates, enabling us to provide just-in-time delivery for all your production parts.

See What Our Customers Say About Us

A customer’s words have a more substantial impact than a company’s claims – and see what our satisfied customers have said regarding how we fulfilled their requirements.

FAQ's

Rapid prototyping (RP), or Rapid prototyping manufacturing (RPM) technology, refers to the general term for the rapid manufacturing of 3D physical entities of arbitrarily complex shapes directly driven by CAD models. This is an advanced manufacturing technology developed in the 1990s. It is a key common technology that serves the development of new products for manufacturing enterprises. It is useful for promoting enterprise product innovation, shortening the development cycle of new products, and improving product competitiveness.

Rapid prototyping can directly accept product design (CAD) data without preparing any molds, tools as well as tooling fixtures, and fast manufacture new product samples, molds, or models. Hence, the popularization and application of RP technology can greatly shorten the development cycle of new products, reduce development costs, and improve development quality. From the traditional “removal method” to today’s “growth method”, from mold manufacturing to moldless manufacturing, this is the revolutionary significance of RP technology for manufacturing.

Rapid prototyping technology discretizes the complex three-dimensional processing of an entity into a series of layered processing, so it greatly reduces the processing difficulty and has the following features:
1. The rapidity of the whole forming process is workable for the modern and fierce product market.

2. It can produce three-dimensional entities in any complex shape.

3. It is directly driven by the CAD model so as to reach a high integration of design and manufacturing. Its intuitiveness and simplicity for modification provide an excellent design environment for perfect product design.

4.During the molding process, special fixtures, molds, and tools are not needed, which saves costs, as well as shortens the production cycle.

5.The high integration of technology is not only the inevitable product of the development of modern science and technology, but also their comprehensive application, with distinctive high-tech characteristics.

The above features lead to the fact that rapid prototyping technology is major suitable for new product development, mold and model design and manufacturing, complex-shaped parts manufacturing, rapid single-part, and small-batch parts manufacturing, as well as shape design inspection, difficult-to-process materials manufacturing, assembly inspection and rapid reverse engineering.

3D printing technology is a collective name for a series of rapid prototyping technologies. The basic principles of 3D printing technology are all laminated manufacturing. The rapid prototyping machine scans the cross-sectional shape of the product in the XY plane and intermittently shifts the thickness of the layer in the Z coordinate. Finally, a three-dimensional part is formed. Currently, the rapid prototyping technology is divided into 4 types, they are Fused Deposition Modeling (FDM), 3DP technology, selective laser sintering (SLS), Stereolithography Appearance (SLA), and Laminated Object Manufacturing (LOM).

FDM technology is to heat and melt filamentous hot-melt materials. At the same time, under the control of the computer, the three-dimensional spray head selectively coats the material on the worktable based on the cross-sectional profile information and forms a layer of cross-section after rapid cooling. After one layer completes the formation, the machine table is lowered by one height (that is, the layer thickness) and the next layer is formed until the entire solid shape is finished. There are various types of molding materials, and the strength and precision of molding parts are quite high. This technology is mainly applied to small plastic parts.

SLS technology is to first spread a layer of metal powder or non-metal powder material on the worktable, and when under computer control, let the laser sinter the solid part of the powder according to the interface profile information, and finally continue to repeat the previous process, form the layer one by one. This method has a simple manufacturing process, fast forming speed, low cost, a wide range of material selection, and is mainly used in the casting industry to produce rapid molds directly.

There are 7 distinguished differences between SLS and SLA technology of Rapid Prototyping. You can find more details as follows:
1)Process principle
The process principle for SLS is to generate the high temperature by the laser to raise the temperature of the powder to the melting point for sintering, while for SLA is to generate ultraviolet light by the laser and irradiated on the surface of the material for curing.

2)Resolution rate
Both technologies use laser beams to cure building materials, but they use completely different wavelengths: ultraviolet light for SLA, while infrared light for SLS. Correspondingly, the intensively irradiated area is also different, the ultraviolet light area is much smaller than the infrared light area. Therefore, generally speaking, the resolution of SLA is higher than that of SLS.

3)Mechanical behavior
SLS printers can use many materials in powder form, and the most common one is nylon (PA12), its properties (like color, strength, elasticity, hardness, etc.) can be changed with additives. This material has excellent performance: sturdy, durable, as well as anti-wear.
As for SLA printers, manufacturers usually use their own resin materials, and many third-party options can be chosen, relatively the price is cheaper. Generally speaking, resin materials are harder than nylon, so it is weaker.
Another important difference is their performance under load: the hard resin will become fragments under severe impact, while nylon has a certain degree of elasticity and can be restored to its original state.

4)Visible surface
Solid material with pores will be formed on the visible surface of the product printed by SLS because the air in the powder forms very small bubbles on the sintered material, which will feel a bit rough when touching. And the surface of SLA printed objects will be much smoother.
Besides, nylon powder usually has three colors: black, white as well as gray, while the resin material can generate any colors through white or transparent resin and pigments.

5)Supporting structure
SLA printing technology requires a supporting structure. The printed parts need to be manually cleaned when using a supporting structure, which will take some time. In addition, please note that the supporting materials should be the same as the raw materials used in SLA printing technology. On the contrary, SLS printing technology is one of the few examples that does not require any supporting structure, because the unsintered powder acts as a supporting structure during the printing process.

6)Post-processing
Although the printed products of them can be post-processed, there are still some differences. And we should check with the professional supplier before doing post-processing. For example, polishing is not needed for SLA printing parts.

7)Cost
Nylon is a common material, and the single output of SLS technology is quite large, so SLS technology is usually cheaper than SLA technology.

The basic principle of rapid prototyping technology is: to split the three-dimensional data model in the computer so as to get the profile data of each layer. Based on this information, the computer controls the laser (or nozzle) to selectively sinter the powder material (or curing layer after layer of liquid photosensitive resin, or cutting layer after layer of sheet material, or spraying layer after layer of hot melt material or adhesive) layer by layer. The sheet-like entities are then piled up layer by layer by means of fusion, polymerization, bonding, etc., and finally the designed new product sample, model, or mold is manufactured.

5)Supporting structure
SLA printing technology requires a supporting structure. The printed parts need to be manually cleaned when using a supporting structure, which will take some time. In addition, please note that the supporting materials should be the same as the raw materials used in SLA printing technology. On the contrary, SLS printing technology is one of the few examples that does not require any supporting structure, because the unsintered powder acts as a supporting structure during the printing process.

6)Post-processing
Although the printed products of them can be post-processed, there are still some differences. And we should check with the professional supplier before doing post-processing. For example, polishing is not needed for SLA printing parts.

7)Cost
Nylon is a common material, and the single output of SLS technology is quite large, so SLS technology is usually cheaper than SLA technology.

1. As the earliest rapid prototyping manufacturing technology, it has been highly developed.
2. Has fast processing speed and a short production cycle.
3. It can process prototypes and molds that have complex structures or difficulty informing.
4. Visualize the CAD digital model and reduce the repair cost.
5. Provide samples for tests, which can verify and check the results of computer simulation calculations.
6. It can be operated online and remotely controlled, which is beneficial for production automation.

The most outstanding advantage of SLS is that a wide range of materials can be used for it. Theoretically, any powder material that can form interatomic bonds after heating can be used for SLS, including paraffin, polymer, metal, ceramic powder, and their composite powder materials. Because of the wide variety of SLS molding materials, the wide distribution of molding properties, material savings, suitability for multiple purposes, and no need to design and manufacture complex support structures, SLS has been more and more popular and widely used nowadays.

The rapid prototyping process includes: pre-processing (the construction of the three-dimensional model, the approximate processing of the three-dimensional model, as well as the slicing of the three-dimensional model), layered overlay molding (the manufacturing of the cross-sectional profile and the overlap of the cross-sectional profile) and post-processing (like surface treatment, etc.)

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