What Materials Should I Use for My Product Prototype?

Choosing the right materials for your product prototype is a critical step in the design process. The materials you select will affect everything from performance and durability to cost and speed of development. Understanding which materials best suit your prototype’s purpose will help you make smarter decisions and avoid unnecessary delays.

This guide explores common prototyping materials, when to use them, and how to match them to your design needs.

1. Understanding the Purpose of Your Prototype

Not all prototypes are created for the same reason. The goal of your prototype will shape which materials you use. Ask yourself: Are you testing form, function, usability, or presentation?

Form prototypes are used early to explore shape and ergonomics. These often use inexpensive materials like foam, cardboard, or PLA (polylactic acid). They’re easy to cut, shape, or 3D print.

Functional prototypes test the mechanics or performance of a product. These usually require tougher, more realistic materials. ABS plastic, aluminum, or even silicone might be needed, depending on the part.

User testing prototypes must feel more like the final product. Materials should reflect the end-user experience, including texture, flexibility, and weight. Soft-touch coatings, rubberized grips, or high-quality plastics may be appropriate here.

Presentation prototypes are often used in pitches or investor meetings. These should look like the final product, even if they don’t function perfectly. High-end finishes, color-matched surfaces, and visual polish are key.

Tip: Clarify the purpose before selecting materials. It will save time and reduce costs.

2. Common Materials Used in Prototyping and Their Benefits

Product design firms typically use a wide range of prototyping materials depending on the stage and function of the prototype. Here are the most common:

PLA and ABS Plastics

Used in 3D printing, both PLA and ABS are common for early-stage models. PLA is biodegradable and prints easily. ABS is stronger and more heat-resistant but requires higher print temperatures.

• Best for: Concept models, initial design tests
• Advantages: Affordable, fast turnaround, good surface detail
• Limitations: Not ideal for mechanical testing or high-stress parts

Polyurethane and Urethane Casting

Polyurethane is used in cast prototypes for parts that need strength, flexibility, or rubber-like qualities. Urethane casting allows low-volume production of parts with qualities close to injection-molded plastics.

• Best for: Short runs, user testing, simulating production parts
• Advantages: Realistic feel, strong, customizable finishes
• Limitations: Slightly higher cost and longer lead time than 3D printing

CNC Machined Plastics and Metals

CNC machining allows for highly precise parts from actual production-grade materials. Engineers often use Delrin, aluminum, or acrylics for mechanical testing or fitment trials.

• Best for: Functional prototypes and engineering validation
• Advantages: High accuracy, strong materials, production-quality finish
• Limitations: Slower to produce, more expensive, limited shape complexity

Silicone and Rubber

Silicone is flexible, heat-resistant, and skin-safe. It’s used for medical prototypes, wearable devices, and flexible seals. Rubber and elastomers are also common in grip components or seals.

• Best for: Soft-touch parts, seals, gaskets, ergonomic testing
• Advantages: Flexible, durable, skin-safe
• Limitations: May need custom molds, which add cost

Foam, Cardboard, and Wood

For early-stage form studies, these materials are quick and inexpensive. Industrial design teams often use them to explore shape and proportions.

• Best for: Initial mock-ups, size studies, brainstorming
• Advantages: Easy to cut or modify, very low cost
• Limitations: Not suitable for mechanical or functional testing

Note: Combining different materials in one prototype is common. You can use hard materials for structure and soft materials for touchpoints.

3. How to Choose the Right Prototype Material

Selecting the right prototype material depends on several key factors. Here are the main ones to consider:

1. Functionality

What does the prototype need to do? If it’s only for display, surface finish and color are key. If it needs to withstand stress or heat, strength and thermal resistance matter most.

• Example: A wearable device prototype should include skin-safe, flexible materials if it touches the user.

2. Manufacturing Method

Different materials are compatible with different processes. 3D printing works well with PLA, resin, or nylon. CNC machining is ideal for metal or hard plastics. Casting may require silicone molds.

• Know your method before choosing the material. It will affect cost and feasibility.

3. Cost and Quantity

Early prototypes should be affordable and easy to revise. For mass production simulations, materials may be more expensive, but more realistic.

• Small run? Use urethane casting or 3D printing.
• High fidelity? Consider CNC or injection mold simulation materials.

4. Speed of Production

Some materials are faster to work with. 3D printed plastics can be turned around in a day or two. CNC and casting may take longer but offer better performance.

• Need it fast? Opt for PLA or resin prints.
• Need it functional? Wait for CNC or urethane parts.

5. User Experience

If you’re testing with real users, appearance and feel matter. Choose materials that match the final product’s weight, texture, and comfort.

• Don’t overlook finishes. Smooth, polished, or soft-touch surfaces can be added even to basic materials.

Pro tip: A product design firm can help balance these factors. Their experience reduces risk and avoids costly errors.

Material Choices Matter for Prototyping Success

The materials you choose for your prototype will shape the entire development process. Early-stage models should be quick and cost-effective. Later-stage prototypes need to look, feel, and function like the final product.

PLA, ABS, urethane, CNC-machined metals, silicone, and foam all have unique strengths. Knowing when and how to use each one can save time and money. And in the hands of experienced designers, even basic materials can create powerful results.

How Spark Innovations Can Help You Choose the Right Materials

At Spark Innovations, we guide you through every step of the product development journey—including material selection. Our team of industrial designers, engineers, and prototype specialists ensures your prototype matches your goals.

We don’t just build something that looks good—we make sure it works, feels right, and is ready for production. Whether you need a rough model, a functional test piece, or a stunning investor prototype, we have the tools and expertise to deliver.

With over 30 years of experience, we’ve helped hundreds of clients across industries turn ideas into real, market-ready products.

Let Spark Innovations help you make smarter prototyping decisions. Reach out to us today to discuss your project needs.