The First prototyping method I use is 3D Printing the model at a reduced scale for quick iterations. These parts have been scaled down by 1/8th scale. The center part represents a mached part interlocking with steel plates.

After developing the design through 3D printing I then use full scale plywood sheet to represent the steel, this was used to check clearance and full scale fitments with other parts.

A hot glue gun was used to simulate a welder and test the clearance required for assembly.

This sheet cost me approximately 58$ but If I got it cut out of steel it would be starting at a cost of 3000$ to potentially be waisted on a bunk design.

After testing out the design in plywood the next step was full scale steel and welding to test out the fabrication process.

This process is repeated until the design is completed.