Using prototypes is always smart when creating industrial systems because you can test out your ideas in real-time. Expanding foam can be used to create these sorts of prototypes and as long as you keep a couple of things in mind, you'll have ample success.
Make Sure Foam Can Maintain its Predetermined Dimensions
You can have more success testing prototypes made out of expanding foam when their dimensional properties remain the same. You'll determine what these specs are before creating the said prototype, but as long as they don't change, you can continue gaining valuable data out of each test that's performed.
Try to find expanding foam that is structurally stable once it fully cures in the mold that you're using to create a prototype for an industrial part or system. Then you won't have to keep creating more prototypes because dimensional properties are thrown off.
Look for Expanding Foam That Can be Carved
After creating an industrial prototype using expanding foam, you may want to perform some adjustments to the mold directly rather than re-casting. You'll have an easier time with this if you make sure you end up with expanding foam that takes well to carving.
You can then shave/cut off any section you want to leave behind a smooth and even surface. Having the ability to work with expanding foam in this way saves you from having to constantly create new molds and waste resources. You can refine your foam prototypes directly and then cater to subsequent molds around them.
Rely on a Lightweight Foam Product
Expanding foam can feature a lot of different attributes, but for prototyping purposes, you might be better off focusing on lightweight foam products. Then you'll have fewer issues moving them around to various testing sites. You won't need any special equipment or professional assistance.
The weight ratings should be listed for every expanding foam product on the market. Just make sure you review the projected weight based on a certain quantity of foam product used after it has time to dry. Then you can easily find a foam product with lightweight properties that are convenient to work with.
There are endless ways you can design industrial prototypes when expanding foam is used. As long as you verify you're going with the right variety and work with it in favorable ways, you're going to refine industrial parts a lot sooner and then start making a profit from them.