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Functional testing with rapid prototypes is confined to certain areas due to a number of issues: the lack of a reliable similarity method that can solve distorted similarity problems; limited material choices; range of prototype sizes; and distinct material structures between prototypes and actual products. Methods are thus needed to expand the application of functional testing with rapid prototypes, and thus potentially impact the performance and cycle times of current product development processes. In this context, an improved similarity method that utilizes a geometrically simple specimen pair is developed in this paper. A realistic numerical simulation and an experimental mold design example (using a selective laser sintering prototype) demonstrate the validity and impact of the new method.