Ideally you will want to produce prototypes regularly spaced throughout the development process starting with simpler cheaper rigs and moving towards more complex accurate models as you progress.
Nowadays with the use of computer aided design, and especially AI aided design, it is easy to jump ahead in the design process, but the learning from physical prototypes is invaluable. We recommend making prototypes before all key decision points such as: committing to a singular concept, investing in IP, choosing a manufacturer, and investing in tooling or other pre-production costs.
Time frame
How long this will take will depend on the stage you are at and how much work has already been done. Before a prototype can be made, the product needs to be designed to a corresponding level.
During concept design simple 2D pencil sketches can lead to rough card or clay models that give a better idea of the 3D form and basic functionality. This can be done in an afternoon.
Once the product is engineered you will want to make what we call a Works-like-looks-like prototype. This is meant to represent the final product as closely as possible with prototype materials and processes.
Step 1: Have an idea
First you need a product idea. This should include an understanding of the problem a product is solving and some ideas of potential ways to solve it.
Step 2: Refine the design
In order to make a useful prototype you will need to explore the idea further, getting a good idea of shape, size, and parts. How refined this needs to be will depend on the complexity of the prototype. This is the time to seek out product designers as experts in the development process.
Step 3: State your Goals
Decide what you want from the prototype. To make best use of your time and budget, it is important to get an understanding of what you aim to gain from the prototype and communicate this to all involved.
Do you need to test all functions, or just one? Does it have to be full scale? Perhaps you need the prototype to look good for photography but functionality is less important? Do you intend to test it with potential users?
Step 4: Choose a method
Find a prototyping partner and decide what build method best delivers your goals. Those who are technically inclined or have a very simple product may be able to go direct to a craftsperson or prototyping specialist or even make it themselves.
Otherwise it is often best to work with a product designer who can make in-house or organise outsourcing and combination of various elements.
Materials and production methods are chosen here. It is often not possible to use the same approach as you would for products on the market, due to the investment or time required.
Good approximations are chosen such as 3D printing in place of plastic injection moulding, hand fabrication in place of casting or stamping, and painting in place of dye or plating.
A cost is agreed at this stage.
Step 5: Create the prototype
The prototype parts are created and assembled based on the agreed method.
Depending on the prototyping method there may also be some trouble shooting and adjustments.
Remember: prototyping is part of the design process, and this is the first time the idea has been made real, so there are bound to be some surprises and setbacks and a good prototyping partner will be able to adapt as they work.
Step 6: Evaluate the prototype
We make prototypes to learn the shortcomings and improve the design, whether these are technical, functional, user-based, or market based.
Review the prototype in depth and take detailed records. These will be crucial to look back on later.
Has the prototype achieved the goals you set for it? What are the next steps?
Common Mistakes to Avoid
- Don’t make a prototype that is more complex than you need it to be, A lot of time and money can be wasted and opportunities for superior designs missed because assumptions are not checked with models early and often.
- One prototype does not have to do everything. Sometimes it is more effective to have two separate prototypes: one with pristine looks, and one with functionality. That way you can test the function roughly without worrying about marring the finish for marketing photography.
Success Indicators
A successful prototype is not one that works perfectly. It is one that gives you the most valuable learning about the design for the investment you put into it.
If there are no failures, you do not know if the design is efficient or heavily overbuilt.