Prototyping Golden Rules

Peeler prototypes for the OXO line of hand-held utensils, created by Smart Design. Smart's work for OXO revolutionized the kitchen tools industry.

Peeler prototypes for the OXO line of hand-held utensils, created by Smart Design. Smart's work for OXO revolutionized the kitchen tools industry.

More quickly than ever the creation of a product prototype is now possible with lower-cost 3D printing and advancements in engineering software. And while what we term “fast and loose modeling” is well-set for this early phase, where mlutiple, rapid prototypes can be produced in quick succession, elements of DFM/DFA should at least be kept in mind (if not practiced), even in this early phase. The reasons for this are many, but can be boiled down to the following adage: “Why model something you can’t ultimately manufacture?” It makes sense to be aware of and plan for the DFM/DFA elements that will need to “be there” when moving from prototyping into a manufacturing mindset. Further, when taking this step to “make your idea real” in the prototyping phase, keep in mind these additional golden rules of prototyping as they will likely save you a great deal of pain:                                                                                                  

1: Simple is Key

The number one rule is to keep things simple. Less parts, easier assembly, less complex all spell lower cost and higher chance of success.

If you’re new to 3D printing technology, start small and basic by designing shapes like cubes and cylinders, just to get the hang of your machine. Plus, the main target of prototyping (especially early prototyping) is to realize your product concept in a very simple way. You can get very early, very rich feedback by getting a rough, physical form factor built and evaluated. Taking the industry view, the goal is to understand what the customer needs and find the easiest way to achieve it through your prototype.

 

2: Your Original Prototype Will Surely Change

A frequent mistake in product prototyping is becoming too attached to your first design(s). Being willing to flex, change, reduce and pivot is key in taking advantage of prototype-driven user feedback and moving your idea closer to one that will be best understood and used. As professional creators of prototypes, you can expect us to be as objective as possible when designing your prototype. Through the design process, there are a number of different things that may drive a change:

  • Aesthetics and/or ergonomics

  • New trends in technology, including sub-components

  • Updates on product functionality

  • Addition of more features

  • Syncing customer’s expectations

  • Changing trends in the industry

  • Optimization of raw material(s)

In product design the only constant is change, and always for the better. Don’t fear change in the design process…rather, embrace it. Changes, especially when done to reduce complexity, ensure ease of manufacturing and assembly, make strong fiscal sense. Your initial design should guide but not dictate the design process.

 

3: Prototype Doesn’t Replace the Final Product

This is an important element. Prototypes are usually meant for visual representation only, but may also be “fully-functional” using selected components, PCB’s, etc. All that said, too much time can be wasted on trying to make prototypes look perfect.

The prototype should strive to convey the product idea, validate the idea with users and stakeholders, show how the product is supposed to work and how they will gain benefit from it. This may be done in conjunction with mocked-up UI/UX screens (which we also enjoy creating).

The final product will follow the rough guidelines of the prototype, but will need to change according to Design-for-Manufacturing (DFM) and Design-for-Assembly (DFA) purposes. As things move forward, imagine multiple prototypes built in quick succession. Quick changes made in reaction to user and stakeholder feedback allow for the product concept to rapidly innovate.

 

4: Don’t Stop Innovating

Innovation is a key, determining factor in the success of a product. Finding better ways to solve problems old and new is the driver here and innovation is the engine. During the design of a strong product for a client, the prototyping phase allows for frequent experimentation with various design concepts to reach maximum efficiency and best operations. It’s in this prototyping phase that you can really reduce costs by switching out raw materials, changing the look and ergonomics of the product, or adding/taking away core features that strongly influence core function. Prototyping is the sole stage where you can make big changes to the product without impacting downstream manufacturing. Take advantage of it!

 

5: Ask the Experts

Stuck in the product design process? Can’t find the right material to prototype with? Maybe you have only a napkin sketch? Or maybe you just need some tips to get better at prototyping? Well, ask us, the experts, and we’ll steer you in the right direction. That said, there are many on and offline resources that go into greater detail on the product prototyping process. Further, meeting industry experts to get first-hand knowledge of their processes can be invaluable. Whatever you do, don’t stop your education. As an unofficial graduate of The School of Youtube, well, I’ve learned a TON about the protyping process by simply watching videos of others. It’s free!

 

Final Thoughts

In a nutshell, the product prototyping process is a combination of technical expertise, experience and creativity. If you embrace these golden rules of product prototyping, you can design and get built the perfect prototype to advance and test your ideas. That said, this is what we do, so we’d be excited to jump in and guide the process with you learning along the way. Contact us here.





Dan Meyers