How to prototype like a pro: Get your product to market faster!

Overcoming the challenges of prototyping to bring your product to market involves a mix of strategic planning, effective tools, and agile processes. So, how can you streamline your prototyping process and get to that vital product stage more efficiently? This blog will give you a few tips.

So, first of all, let’s start with prototyping challenges. What are they? What are some of the key challenges?

1. Cost Constraints
2. Time Constraints
3. Complexity
4. Resources
5. Security
6. Feedback, Testing and Iteration
7. Quality Assurance
8. Communication

Now we have our challenges; how do we overcome them? Or work around them?

Challenge 1: Cost Constraints—High-quality materials and tools can be costly, and each iteration will only increase the cost.

• Define your Prototyping objectives: What do you want to achieve with each prototype? Are you validating a concept? Testing functionality? Demonstrating a product? What are the key features that need to be tested? What functionality is it important to test? Do they all need testing? You must go into your prototyping phase knowing precisely what you want to get from it; this will benefit you from both a cost point of view and time.
• Materials: Consider what materials fit within your prototyping budget. If you can’t afford to prototype the material you plan to use in the end product, is there a cheaper material with the same characteristics? Do you need to physically prototype the whole part? Reducing the amount of material used can also lower your cost.
• Process: Which process do you plan to use? Do you need to use the same process for prototyping as you do for the end-product? Is there a cheaper option that could be used? For example, you plan to use injection moulding for your final product as you will eventually need to ramp up production. However, the material is available for 3D printing, which would be a much quicker and probably cheaper option for prototyping your part.
• Outsourcing: Using a seasoned supplier to support your prototyping and production needs will cut down on your costs. You won't have to spend a lot of cash upfront on machinery, software, and expertise.

Challenge 2: Time Constraints – Market pressures can lead to rapid turnaround time requirements, and extended development cycles can lead to a time-consuming and delayed project timeline.

• Materials: Some materials are quicker to process than others, and some require finishes to provide the required functionality.
• Service: Which service do you plan to use? Depending on complexity/ material, etc., one service may prove quicker to prototype your part than others. 3D printing tends to be the go-to for prototyping. However, it may not always provide the material, finish or tolerances you require.
• Outsourcing: Use a supplier who has the capacity and expertise to turn your parts around quickly and efficiently and to meet the standards you require.
• Feedback: Use design for manufacturability software. Get feedback on your part and potential issues quickly, fix them, and re-upload. Keep looping around until you are ready for physical prototypes.

Challenge 3: Complexity – Complex designs can be timely, costly and inefficient. They may also require technical expertise to manufacture without issue.

• Supplier: Choose a supplier that offers the complexity you require.
• Service: Which service will you use? Complexity can significantly impact which service is most suitable for your prototype. Also, different suppliers offer different tolerances, geometries, features, etc.
• Technical Support: If your part is complex, you may have to iterate your design a few times before it is manufacturable by your supplier. Use a supplier who provides feedback and offers technical support.
• Break Down: Can you break down complex designs into smaller, more manageable modules? Prototype each element individually.

Challenge 4: Resources—Limited access to tools, materials, and expertise often makes outsourcing your manufacturing a good idea.

• Outsourcing: Do you have in-house machinery to manufacture your part? If you do, do you have enough capacity to fulfil your needs? And the expertise to carry it out? Most companies utilise a manufacturing partner. What things do you want in a partner?
  Ideally…
  • The service/s you require.
  • The material/s you are opting to use.
  • Provide Feedback and Technical Support.
  • A Supply Chain that is not easily impacted.
  • Communicates openly and collaborates with you.
  • Minimum order quantities.
  • Bridge Tooling (From prototyping to production).
  • Production Runs.