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The use of rapid prototyping in the development of five fans for the International Space Station is reviewed, showing how the design cycle has been reduced by more than 75% through the use of rapid prototype hardware test articles. A case study shows how rapid prototyping was used to produce a fan's two housings and how four separate impellers were designed, fabricated and tested in a five week period. Both aerodynamic and acoustic performance of the rapid prototype hardware were validated by flight-version metal assemblies. Using the improved development process where only two parts are changed to existing space-qualified fans shows that a broad range in flow and ΔP capability exists for designs targeted to specific operating points.