Rapid Prototyping & 3D Printing


Fast and Full Service Prototyping

Bring your idea into reality.

We offer a wide range of product development services. SourceSync specializes in delivering you accurate and functional prototypes right out of the box. We deliver prototypes from high resolution SLA models to high durability FDM parts in as little as 1-3 days. We will provide you with the right process and deliver exactly what you need to complete your task. From rapid prototyping and prototype development (Objet 3D printing, Stereolithography SLA, CNC machining, custom model making) to prototype tooling and reproduction (silicone molding and urethane casting), to manufacturing consultation and production management.

Our dedicated and experienced staff of designers, model makers, and technicians offer solutions every step of the way. We help you decide which process is best for your application and help to achieve the best possible parts in the shortest lead time. Each technology has its own strengths and weaknesses, and having access to many options allows you to complete your full project with one provider to reduce costs and timing.

We strive to deliver quality services and parts with courtesy, sensitivity and the minimum delay, fostering a climate of mutual respect between provider and customer. SourceSync trys our best to provide choices, where feasible, in service, delivery and payment methods, location of contact points, opening hours and delivery times to help provide that one on one feel of fulfilling your prototyping needs. We strive to meet all your needs in quality and service for in return your customer loyalty. If you have any questions or would like any more information on our company or the services we can provided for you please don't hesitate to contact us.

Rapid Prototyping

Time is money. We'll save you both.

While rapid prototyping isn’t new, it is more important than ever before. Using leading-edge technologies, SourceSync takes you from the drawing board to the testing table within days, rather than the weeks required by traditional manufacturing techniques. From plastic and metal machining to 3D printing, we have the tools to get you working prototypes cheaper and faster. Time is money – so why not save both?

Low-Volume Prototypes

From concept models to functional prototypes.

Product testing is integral to any product launch, and SourceSync makes it easy for you to move from design to working prototypes in just a matter of days. Working from an STL file, we produce prototype batches as small as one part, detecting early design flaws, increasing product output and reducing costs – without spending time and money on expensive tooling. No matter the size of your prototype run, SourceSync guarantees precision parts to help you bring your product to market.

Find the Perfect Prototyping Technology For Your Design

SourceSync will analyze your manufacturing needs and choose the right technology to suit your project. We use PolyJet 3D Printing, CNC Machining, Direct Metal Laser Sintering and other advanced manufacturing techniques to streamline your prototyping and production manufacturing needs. Reduce project cost and risk Refine and iterate design concepts quickly Deliver high-quality products on-time and on-budget Avoid costly tooling modifications during production – just simply tweak your design files

3D Printing Technologies

3D Printing technologies offer transformative advantages at every statge of the product development life cycle. The small size, ease of operation and high speed of the 3D Printing process reduces time-to-build and facilitiates innovation and experimentation. Also known as additive manufacturing, 3D Printing provices freedom and flexibility from conventional manufacturing methods. SourceSync uses the processes below for rapid modeling, prototyping and production of end-use parts.

Additive Manufacturing

The next generation of manufacturing.

While traditional manufacturing methods turn raw materials into product, Additive Manufacturing builds your product from the ground up by depositing layers of sintered metal or plastic. With Additive Manufacturing, producing complex parts in production ready materials takes days instead of weeks. From prototype to production, SourceSync's Additive Manufacturing technology will help reduce your time to market and production costs.

A Flexible Soution for Complex Parts

Additive Manufacturing technologies provide incredible advantages over traditional manufacturing and machining techniques. Rather than removing material to create a product or prototype, SourceSync produces parts by printing your design layer by layer. This offers unparalleled precision and replaces the need for expensive multi-axis machining. SourceSync provides the easiest and fastest way to turn a 3D CAD design into a production-ready part.

FDM

Fused Deposition Modeling: Like most other additive fabrication processes (such as 3D printing and stereolithography) FDM works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle which can turn on and off the flow. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided design software package. The model or part is produced by extruding small beads of thermoplastic material to from layers as the material hardens immediately after extrusion from the nozzle. Several materials are available with different trade-offs between strength and temperature properties. As well as acrylonitrile butadiene styrene (ABS) polymer, the FDM technology can also be used with polycarbonates, polycaprolactone, polyphenylsulfones and waxes.

Objet

Objet: The PolyJet process provides fine detail and surface finish in prototypes and manufactured parts. In a process similar to ink jetting, liquid photo polymer resin is jetted out in fine layers to build a model. The layers measure only 16 microns (0.0006 in.) which results in a superior surface finish smoothness. The materials are jetted in ultra-thin layers onto a build tray, layer by layer, until the part is completed. Each photopolymer layer is cured by UV light immediately after it is jetted, producing fully cured models that can be handled and used immediately, without post-curing. It offers the completely unique ability to print parts and assemblies made of multiple model materials, with different mechanical or physical properties, all in a single build. Taking the revolution even further! Printing with Digital Materials allows you to print parts with specific Shore A values to match the values of the intended production materials. This capability opens up new opportunities, bringing you much closer to realizing the final product at an early stage, including feasibility testing and over-molding process simulation.

Z-Corp

Z-Corp: Is a process where a plaster or starch based powder is spread out in layers from .0035" to .005" in thickness and the layers are bonded by cyanoacrolyte and ink for color. These models can be printed in monochromatic or in multiple colors at one time to produce a like-finished look for marketing models in just a few hours. The colors can be chosen in most CAD software and are exported with the model when saved as a VRML file. This process is very fast, and relatively inexpensive compared to the other processes, but may not provide the strength or flexibility of the others.

Urethane Castings

Urethane Castings: To start the mold making process, a master pattern is needed; it can be a part you supply, or a stereolithography prototype that has been finished. The master pattern is coated in a silicone-based liquid rubber. Once the liquid hardens, the master pattern is removed, and the void left behind is injected with a urethane casting material that best fits your material requirements. Using this process, several copies, or urethane castings, can be made of the initial prototype.

SLA

StereoLithography: Is an additive fabrication process utilizing a vat of liquid UV-curable photo-polymer "resin" and a UV laser to build parts a layer at a time. On each layer, the laser beam traces a part cross-section pattern on the surface of the liquid resin. Exposure to the UV laser light cures, or, solidifies the pattern traced on the resin and adheres it to the layer below. After a pattern has been traced, the SLA's elevator platform descends by a single layer thickness, typically 0.05 mm to 0.15 mm (0.002" to 0.006"). Then, a resin-filled blade sweeps across the part cross section, re-coating it with fresh material. On this new liquid surface the subsequent layer pattern is traced, adhering to the previous layer. A complete 3-D part is formed by this process. After building, parts are cleaned of excess resin by immersion in a chemical bath and then cured in a UV oven.

SLS

Selective Laser Sintering: Is an additive rapid manufacturing technique that uses a high power laser to fuse small particles of plastic, metal, ceramic, or glass powders into a mass representing a desired 3-dimensional object. The laser selectively fuses powdered material by scanning cross-sections generated from a 3D digital description of the part (for example from a CAD file or scan data) on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness, a new layer of material is applied on top, and the process is repeated until the part is completed. SLS can produce parts from a relatively wide range of commercially available powder materials, including polymers (nylon, also glass-filled or with other fillers, and polystyrene), metals (steel, titanium, alloy mixtures, and composites) and green sand.

With all thee different technoogies, SourceSync enables you to choose the best prototyping mthod to suite your needs. The following chart was designed to aid you in your rapid prototyping technology selection. The numbers below are based off of typical material averages and are meant as a general guide. Further, our knowledgeable project engineers are well versed in prototyping and production technologies and are available to help guide your project to the best technology.

Rubber Design Guide

3D Printing Design Guide (PDF)

New to 3D Printing? This guide has everything you need to get started.

Vacuum Casting

Besides additive techniques, SourceSync offers another type of Rapid Prototyping: manufacture of components and small series in silicone molds. Vacuum casting lead times are a bit longer than with 3D Printing technology but the result is astounding. Products made in silicone molds have a quality comparable to the final product, which makes them especially suitable for fit and function testing and marketing purposes. The method uses cast silicone molds made as follows: a master model (that typically originates from stereolithography or selective laser sintering) is carefully prepared to ensure a high quality finish to the surface and the definition of the parting planes. Silicone is cast around the master, partially under vacuum in order to avoid air bubbles being trapped in between the master and silicone. After curing, the mold is cut according to the parting planes and the master is removed, leaving a cavity to make copies. The flexibility of the silicone allows limited undercuts, which might avoid slides or additional parting planes.

Two-component polyurethanes are typically used as copying material. This allows fast production of high quality parts. Vacuum casting is a copying technique typically used for the production of small series (10 to 20) of functional plastic prototypes.

Rubber Design Guide

Vacuum Casting Design Guide (PDF)

New to Vacuum Casting Design? This guide has everything you need to get started.

3D Printing Applications

3D Printing technology is widely used in industries including aerospace, defense, medical, consumer goods, automotive and architechture. The range of applications includes:

  • Concept Modeling:

  • Concept modeling involves bringing early-stage ideas and concepts to life. Concept modeling is widely used in design, engineering and architecture firms for testing, proofing and fine-tuning raw designs.

  • Rapid Prototyping:

  • One of the key benefits of 3D Printing technology is the ability to make moving parts in different materials. This enables design engineers to produce fully functional prototypes for testing purposes. Rapid prototyping can dramatically increase productivity and help identify errors early in the design process.

  • Rapid Tooling:

  • Our response times and knowledgable design engineers are able to make molds and casts for tools, fixtures and jigs within days, dramatically decreasing production time.

  • Rapid Manufacturing:

  • As a result of decreasing costs and faster production times, SourceSync can use 3D Printing to create end-use parts directly without tooling.

Our team of accomplished engineers are highly proficient in the latest 3D engineeing software with cross-functional experience across various CAD platforms. SourceSync's team also has years of industry experience designing products and materials for diverse applications. We can help develop your idea into a tangible design that can be prototyped within days using technologies such as Fused Deposition Modeling and Selective Laser Sintering. Through strategic relationships, both domestic and in low cost countries, we can help arrange the manufacture of your product to meet your business needs. Whether it be an innovative, small scale idea that requires engineering, prototyping, and design protection, or large scale sourcing solutions and material expertise, SourceSync can assist you with your product development strategy.

CNC Machining

The next generation of manufacturing.

While traditional manufacturing methods turn raw materials into product, Additive Manufacturing builds your product from the ground up by depositing layers of sintered metal or plastic. With Additive Manufacturing, producing complex parts in production ready materials takes days instead of weeks. From prototype to production, SourcSync's Additive Manufacturing technology will help reduce your time to market and production costs.

A Flexible Soution for Complex Parts

Additive Manufacturing technologies provide incredible advantages over traditional manufacturing and machining techniques. Rather than removing material to create a product or prototype, SourceSync produces parts by printing your design layer by layer. This offers unparalleled precision and replaces the need for expensive multi-axis machining. SourceSync provides the easiest and fastest way to turn a 3D CAD design into a production-ready part.

Advantages of CNC Machining

Subtractive technologies are often thought of as old school, but SourceSync is bringing CNC Machining into the next generation. Our leading-edge machines use the latest technology to turn your 3D CAD file into a high-quality, precision production part in as fast as 24 hours. Perfect for low-volume to production quantities Smooth finishes on a solid metal or plastic parts, produced exactly to design specifications Offers high-precision tolerances and easily reproducible processes Lead times of less than a week

How CNC Machining Works

The CNC Machining process can be broken down into three steps:

Step 1: 3D CAD files are analyzed to determine the fixturing required and the most cost effective method to machine the part.

Step 2: Machine code for fixtures and the manufacturing of the part is generated using Mastercam software.

Step 3: The product is then manufactured to the customer’s dimensional and surface finish specifications using high speed, precision CNC machining equipment and tools.

Rubber Design Guide

CNC Machining Design Guide (PDF)

New to Rubber Design? This guide has everything you need to get started.

Injection Molding

Quality parts in high performance plastics.

When it comes to testing real production prototypes, there is simply no substitute for injection molded parts. Traditional machining often requires multiple processes to produce components with complex geometries and intricate construction. SourcSync rapid injection molding eliminates the need for these costly and time-consuming methods by producing a single mold for complex, precision parts that would be too costly to machine. SourceSync is the quickest and easiest way for you to create injection molded parts for prototyping, initial runs and low-volume production. No part is too big, too small or too complicated.

Custom Injection Molded Parts in 15 Days

SourceSync's Injection Molding service gives design engineers a fast and affordable way to get real injection molded parts in prototype or low-volume quantities. We can turn around real injection molded parts astoundingly fast — from order to shipping in as fast as one business day. Protomold delivers in days what used to take weeks: functional, production-representative injection molded parts in hundreds of engineering-grade resins.

Low-Volume Injection Molds and Parts

Low-Volume Production, Without Limits.

You don’t always need a full production run with expensive tooling, and SourceSync's Low-Volume Injection Molds and Parts offers the perfect solution. Low-Volume Injection Molds are the best way to build custom parts with complex geometries in production runs up to 10,000 parts. SourceSync production molds can create parts and inserts with all commercially available resins and surface finishes, with lead times of just 2 – 3 weeks. Our Low-Volume Injection Molds and Parts bring you custom plastic molded parts with no geomertry limits quicker than ever.

Why Choose Low-Volume Injection Molding?

Parts delivered in 2-3 weeks versus 6-10 weeks for production tooling.

Significant cost savings compared to hardened steel production tooling.

All commerically available resins can be used with custom coloring options available.

Simple to complex geometries can be designed into the mold to include side actions, square corners and a variety of surface finishes.

How Low-Volume Injection Molding Works

The LVIM process can be broken down into five steps:

Step 1: 3D CAD files (preferable in .IGS format) are analyzed and your tool design is constructed using the latest 3D CAD software.

Step 2: With the tool design complete, CNC or DMLS machine code is generated.

Step 3: The mold components are created using DMLS technology, high speed CNC machining equipment, EDM processes or a combination of all.

Step 4: Final texturing and polishing are applied.

Step 5: Production begins using commercially available resins and colors.

Rapid Injection Molding

No-frills production part in as little as 3 days.

Rapid Injection Molding offers a quick, affordable way for product designers and engineers to bridge the gap between prototype and production runs. Using your 3D CAD file, SourceSync can quickly produce aluminum tooling and inserts without sacrificing quality. With run quantities up to 10 parts, Rapid Injection Molding is ideal for product engineers who need no-frills production parts in as little as 3 days. When you need custom parts fast, Rapid Injection Molding helps take your production run to the next level.

Advantages of Rapid Injection Molding

When Injection Molding is your choice manufacture plastic parts, several thoughts come to mind – costly molds, long lead times, and expensive design changes. SourceSync's Rapid Injection Molding provides a fast, cost effective alternative to the old approach. Technology, materials and standardization are the tools used by SourceSync to cut the lead times so that parts can be produced within 10 days of the order versus 4-6 weeks at a fraction of the cost. Design changes can also be accomplished quickly and cost effectively. Some limitations do apply with Rapid Injection Molding, but the fast turnaround time allows the prototype process to move faster by quickly providing a fully functional injected molded part.

Why Choose Rapid Injection Molding

Production quality prototypes in hand within 3 – 10 days.

Significantly lower cost than traditional production tooling.

Design changes can be made at a lower cost and faster lead times.

Injection molded quality provides accurate form, fit and function for the parts.

How Rapid Injection Molding Works

The Rapid Injection Molding process can be broken down into four steps:

Step 1: 3D CAD files (preferable in .IGS format) are analyzed and your tool design is constructed using the latest 3D CAD software

Step 2: With the tool design complete, CNC or DMLS machine code is generated.

Step 3: The straight pull mold is made from aluminum or stainless steel using DMLS technology, and/or a high speed CNC Machine.

Step 4: The parts are then injection molded using standard colors and materials.

Rubber Design Guide

Injection Molding Design Guide (PDF)

New to Injection Molding Design? This guide has everything you need to get started.

Low-Volume Rubber and Plastic Prototypes

Low-Volume Rubber and Plastic prototype is perfect for manufacturers and new product designers looking to bridge the gap between final part design and hardened steel production tooling. Low runs provide all the features and finishes desired for an injection molded part in a fraction of the time and cost to produce production tooling. Molds are designed for up to 10,000 cycles, and all commercially available compounds/resins and colors can be used to manufacture your parts.

Application Highlights:

Perform real world testing prior to investing in hard tooling.

Enter the market quickly, build your brand, and ramp up market share while full production tools are being developed.

Great for complicated designs, and market ready production runs.

Silicone Glove

One required a prototype for a functional and aesthetic design of a specialty kitchen oven mitt. The material sourced had to be FDA compliant while withstanding the rigors of heated bakeware. In addition, the customer needed multiple designs to bring to market to allow customers different colors/patterns. We were able to provide the customer with a one cavity prototype rubber compression mold good for thousands of run. Customer now had the ability to make small quantity runs to present ideas to investors and to launch into the marketplace.

Plastic Enclosure

Customer required a small 50 piece run for a plastic enclosure they were designing. SourceSync was able to provide parts with a 15 day turnaround. Parts were dimensionally in tolerance and the customer was able to use the final ABS material which performed identical to their real world application.

Vibration Isolator

Selection of a proper mount is essential in vibration and shock management. We've helped customers combat their NVH issues with our analysis and custom-engineered solutions.

Vacuum Casting

Low-Volume Injection Molding is perfect for manufactures and new product designers looking to bridge the gap between final part design and hardened steel production tooling. LVIM provides all the features and finishes desired for an injection molded part in a fraction of the time and cost to produce production tooling. Molds are designed for up to 10,000 cycles, and all commercially available resins and colors can be used to manufacture your parts.

Application Highlights:

Perform real world testing prior to investing in hard tooling.

Enter the market quickly, build your brand, and ramp up market share while full production tools are being developed.

Great for complicated designs, and market ready production runs.

Vacuum Casting

This customer required flexibility in terms of iterations and design changes. In addition, they wanted the ability to turn out 10-20 pcs. very quickly. Vacuum casting was chosen in this application due to the speed and cost at which parts could be manufactured.

CNC Machining

Rapid Injection Molding is the ideal method to get a prototype run of injection molded parts fast. Rapid Injection Molding drastically reduces lead times and costs, without sacrificing the quality you need to bring your product to market. Rapid Molding can be used for rapid prototyping and short-run bridge tooling.

Application Highlights:

A cost effective means to quickly test several designs without killing the budget.

A means to obtain fully functional plastic parts that will assist in finalizing design parameters.

Quickly get production quality prototypes in the hands of your business development team market testing and new product introduction.

Bell Grommet

Custom designed to retrofit existing assemblies. Tooling required and developed from 3D models.

Manifold Gasket

Geometry extracted from an existing manifold to create the perimeter of the gasket. Gasket overmolded for both rigidity and sealing enhancement. Similar to that of a standard edge bonded gasket, but a fully overmolded gasket provides better performance.

Vibration Isolator

Selection of a proper mount is essential in vibration and shock management. We've helped customers combat their NVH issues with our analysis and custom-engineered solutions.

CNC Machining Materials

SourceSync utilizes the materials listed below to bring you quick-turn, precision machined plastic and metal parts.

SourceSync helps clients drive sustainable improvements to make procurement a source of value and innovation across the enterprise. Our approach supports both full-scale procurement transformations as well as targeted improvements to address key client issues and deliver tangible benefits.

Injection Molding Materials

Selection of the proper material is crucial to part production. Designers should consider the mechanical characteristics, molding properties and cost of the resin used.

Application-specific requirements will always drive the need for particular material properties like tensile strength, impact resistance or ductility.

Successful designs for injection-molded parts are also built on an understanding of process-related issues such as the ability to fill the mold, tendency to flash, ease of part ejection, and the potential for warp, sink or void creation. Part geometry can be used to help address some of these issues, but just as material properties are an important factor in meeting the requirements of a given application, they should also be considered to ensure the moldability of the part.

Generally, any conventionally injection-moldable material can be specified. If the material is relatively standard, and we don't have it in stock, there may be an extra charge for us to procure a minimum quantity. Delivery could also be affected if the material is not readily available from the resin distributors. We are happy to work with specific resins that you already use and would like to supply to us.