From Prototype to Production: the most important paths to Success Part 1

Having a prototype is one thing, but turning it into an actual usable product can be overwhelming. Because of this, many products that are developed to test a concept or process are not pursued. So how do you get from prototype to production?

In this article, you will find detailed information about the transition from prototype to production, the steps involved, the strategies involved, and other important things that will help you to achieve it successfully.

The process from prototype to production

The move from prototype to production is often overwhelming, especially for those new to manufacturing. It’s also a common misconception that this process is the same for all product development ideas, but that’s far from the truth.

The truth is that every manufacturing process is unique, and the same goes for products. Just because a process worked for a product you currently have on the market doesn’t mean it would work for the new product you plan to launch.

The general process from prototype to final product is as follows.

First, develop an idea for the product. The next step is creating an engineering drawing, which is often not easy as you may need to revise the design several times to ensure seamless functionality and manufacturability. The third step in this process is the development of a 3D model of the drawn design. After that, you can make a prototype and test its functionality. This process can also be repeated for optimal product functionality.

After developing and ensuring the functionality of the prototype, the next step is to decide on the desired quantity of the product. This decision determines the type of rapid prototyping injection molding, i. H. the use of soft or hard tools.

Then you can sign the manufacturing contract and manufacture your products or parts. For product parts, it is recommended to assemble them before shipment. While this process may seem linear, there is a lot of back and forth involved in creating a product that meets quality standards.

Now that we know the path from prototype to the production process, let’s discuss each process in detail.

Creating a great digital prototype

If you want to turn your fantastic idea into a product, creating a prototype is the first step in the right direction. Various options for developing prototypes are presented below.

Conceptual prototyping

Conceptual prototyping is all about communicating your ideas and exploring concepts that fit your idea, and it is one of the most cost-effective prototyping methods. This communication makes it easier to identify the basic requirements for production, the key features, and the challenges you might face.

With conceptual prototyping, you can use a styrofoam cutout or sketch to present and communicate your idea.

Function prototyping

Feature prototyping is the process of developing a prototype for parts of a system to gather information about how it works and functionality requirements. This type of prototyping also helps to gather information about the limitations of the developed parts of the overall system.

This type of prototyping is particularly useful for developing parts of a mechanical or electrical system.

Evolutionary prototyping

Evolutionary prototyping is used when a working prototype needs further analysis and modification. Variables that can be changed in this type of prototyping include performance, cost, and availability of materials.

More importantly, this type of prototyping is often continuous as the initial design is tested and evaluated over and over again through to mass production and commercial release.

The estimated timeframe for prototyping

The estimated timeframe for prototyping depends on what stage of prototyping you are in. If you are still in the concept and ideation phase, it can take anywhere from a week to a month depending on how quickly the design is approved. Once the design is complete, prototyping can take anywhere from a few days to a few weeks, depending on the complexity of the design.

For a prototype that needs to be modified, using rapid prototyping would reduce the prototyping time to a few days. However, if you use the traditional prototyping process for this change, the estimated time span is often between a few weeks and months.

If you want to get your prototypes faster, consider Winsun Proto’s prototyping services. Winsun Proto not only creates prototypes within 1 day but also helps you review and iterate your design.

Do Market Research, Test Products

Now you have your prototype. Before production, you need to test its demand and acceptance. How do you do that?

Test the demand for the product

Crowdfunding projects are one of the easiest ways to test demand for your product. If people are willing to crowdfund your project, then that is a clear indication that it will be in high demand after production.

Tooling, sampling, and non-production release

Tooling is the process of turning the prototype from a digital product into a physical sample with various replicas. Sampling aims to evaluate the product, its performance, and functionality and to make any necessary changes before series production.

Tooling and sampling form the non-production release phase, after which documentation for the manufacture of plastic prototypes and other types of manufacturing, such as B. The machining of prototype tools and 3D printed prototypes is essential.

Ensuring that the prototype is suitable for mass production

After the prototype development process, changes can be made to improve quality and eliminate errors. Eliminating defects in the prototype phase would save time and money in production in the long term.

Take Your Product From Prototype to Low-Volume Production

After designing the prototype and ensuring it meets all form and function, aesthetic and fit requirements, it’s time to move on to low-volume production.

In low-volume manufacturing, products are often manufactured in small batches of 50 to a few hundred pieces to meet market demand. Depending on the project, low-volume manufacturing is also a stepping stone to high-volume manufacturing, or it’s all there is.

Below are some points to consider before starting small batch production;

Prepare required documents

Below you will find documents that facilitate small series production;

Product Requirements Document: Also known as a PRD, this document helps define the purpose, value of your product, and its characteristics.

3D Files: This document contains the design files for your prototype. It must be of good quality and detail and define the whole part of the system.

Material, Color, and Finish: Document detailing the color, type of material, and finish for each part of your prototype.

Estimated BOM: The CBOM document contains a detailed cost breakdown for all components included in the prototype.

Non Disclosure Agreement: Also known as an NDA, is an agreement signed with your manufacturer or supplier. Make sure you do not share your project files before signing this Agreement.

Final Prototype Review: This document shows the progress of the prototype and highlights key challenges and issues.

Ideal lead time

This is production time. The lead time is often very short when you outsource your production from the design and prototype phase to the manufacturing phase to a manufacturer. However, the lead time is significantly longer if you hire the manufacturer after your prototype has been developed. The reason for this is that the manufacturer needs to create 3D design models. Another reason for the longer lead time is that the engineers working with the manufacturer need to be trained to manufacture and test the components of your prototype.

Another factor that determines the lead time is the complexity and scale of production. Complex designs often take more time than simpler designs. In addition, the lead time for small series is shorter than for large series.

Total manufacturing budget

Your manufacturing budget largely determines how quickly your product moves from prototyping to low-volume production. With a big budget, low-volume production is often seamless because you give manufacturers the resources to design, make molds, and use the right materials for your project.

On the other hand, if the budget for production is below the optimum, production takes longer.