The present study aimed to assess the effect of implementing Rapid Prototyping (RP) in the product development phase on the sustainability of a conventional supply chain. The sustainability indicators of RP utilization were identified through a critical literature review and consulting two experienced RP practitioners to determine the key variables regarding the potential impact of RP on the supply chain components, with an emphasis on sustainability pillars. A generic system dynamics modeling was provided to simulate the RP-adapted supply chain and measure its sustainability performance. The simulation results indicated that RP utilization in the design phase could decrease the number of the assembly parts and material consumption in conventional manufacturing, while indirectly affecting the reduction of waste generation, logistics, CO2 emissions, processes, and the total costs which are related to environmental and economic aspects of the sustainable supply chain. Findings indicated that significant increase in operational skills and knowledge as the main indicators of the social dimension could remarkably reduce the failure rates and increase the quality of the products. This indicator plays a pivotal role in operational success and could be enhanced through training programs. Social sustainability indirectly affects environmental and economic sustainability. This was the first model-based research to examine the potential effects of RP on the sustainability of a conventional manufacturing. The proposed generic model encompassed the variables that could be applicable in every scenario to help decision-makers change values or add more variables within specific industry settings and choose the applicable ones, which in turn, accelerating the RP adoption in supply chains and providing insights for operational decisions regarding product design stage.

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