Rapid Prototyping

In as little as a few hours, Barron can convert your CAD file or math data file to a prototype pattern for use in your fit, form, or function testing as a pattern. In 2 - 4 weeks, we can deliver a metal cast part, and in as little as 3 - 5 weeks, Barron provides customers with complete cast and machined parts for time-sensitive programs and projects.

Barron Industries featured in  Society of Manufacturing Engineers Video: Rapid Castings Rapid Prototypes for Metal Casting Processes

From 3D model to metal cast part in a matter of weeks

3D Model
Metal Part

The Barron Industries Rapid Prototyping process uses layered modeling techniques to create a precise model or pattern of the proposed investment casting component in resin or wax. Models or patterns are completed in as little as a few hours. The model can then be used as-is or cast to desired specifications in a wide variety of alloys without the expense of additional tooling.

6J3I3896Our Plex® manufacturing and Enterprise Resource Planning (ERP) software eliminates errors and speeds up the rapid prototyping process, while our expert engineers monitor the process and make informed decisions based on real-time data. To ensure the accuracy of every production casting, they use the following four-step process:

  1. Convert the math data or three-dimensional model (3D) into a solid model file and run solidification modeling.
  2. Build and cure the rapid prototype pattern, via a 3D printer (Projet) or Stereolithography (SLA) technology.
  3. Inspect the rapid prototype pattern to ensure it meets both surface finish and dimensional specifications.
  4. Manufacture and deliver the functional investment casting rapid prototype for validation.

We produce rapid prototype patterns using liquid resin or wax with advanced 3D printing equipment. Pattern production via rapid prototype machines provides a distinct advantage to our customers as no tooling is required. This process produces high quality and complex precision casting patterns in a matter of hours.

Frequently Asked Rapid Protoyping Questions

What is a typical lead-time for rapid prototypes?

Rapid prototypes can be made in as little as 2 weeks utilizing the rapid prototype process. Samples that come from simple tooling can take anywhere from 6-8 weeks. Samples from more complicated tooling can take between 8-12 weeks, depending on the complexity of the component and the finishing requirements.

What is the lead-time for production parts?

A great number of variables affect a production schedule. Typically, once a part is production-tool approved, our lead-time is 6-10 weeks. Barron Industries provides “just-in-time delivery” according to the customer’s manufacturing schedules, thus reducing throughput time to only ten days.

When does it make sense to utilize rapid prototyping versus traditional prototype tool building?

Rapid prototyping is best utilized when the client only requires a few parts and anticipates future design changes.

What are the cost drivers for rapid prototypes?

The size and weight, technical complexity of the part, and/or the desired schedule are all major factors in pricing a job.

What information do you need to create a rapid prototype?

At a minimum, the client must supply solid model math data in any format, .stp and .igs are preferred, and a latest revision blueprint with all pertinent technical specifications.


Barron Industries has updated its website, making it easier to use on mobile devices. We also now include pages dedicated to specific industries including aerospace, defense, oil and gas, medical , marine, nuclear, and tool  and die. New photo galleries include samples of the more than 200 ferrous and non-ferrous alloys we pour. In addition, […]