What is Prototype Development?
Definition
To define the phrase, let’s break it down into its constituents. A prototype is a look-alike or a copy of a part that demonstrates the product features and explores all possibilities before investing in the part’s complete development. A prototype can range from a detailed drawing with pen and paper to a fully working version of the product. Therefore, prototype development is simply a series of processes that the manufacturer uses to produce the prototype. Many also refer to prototype development as prototype manufacturing.Categories of Prototype Development
We can classify prototypes into four categories based on the product’s design and how the manufacturers expect the final product to function. The categories include:1. Working Prototype
Just as the name implies, the product developer makes the working prototype exhibit as many of the final product features and functions as possible.2. Functional Prototype
A functional prototype and a working prototype are similar in their development processes. However, the product developers usually make the functional prototype on a different scale and using a different technique.3. Visual Prototype
4. User Experience Prototype
The product developers make the user experience prototype showcase enough details that can help with further research in the product manufacture.Importance of Prototype Development
The prototype development stage is an invaluable process that is important to every part manufacturer. Here are some reasons why part manufacturers cannot overlook the prototype development stage:1. Pitching the Product
There’s no point in making a part or product that the clients or stakeholders will not support. We can all agree that selling a product with a prototype will convince the client/stakeholder more than selling without one. This is because they can touch and feel the prototype and give feedback. Their feedback is also important in making considerable design changes to the final product.2. Putting the concept to the test
3. Minimizing the cost of production
To some, this might seem wrong since the prototype will also consume some of the capital meant for product production. However, the amount used in the prototype production will be insignificant compared to the amount the stakeholders will have to waste if the trial and error method is used. This is because the prototype will help determine all the revisions the manufacturer has to make with the product. Hence, a more accurate estimate of the production cost can be determined.The Difference between a Prototype and the Final Product
Generally, manufacturers and product developers try as much as possible to minimize the difference between the prototype and the final product. The actual product might differ from the prototype in terms of its appearance, the material used, or the machining process. For instance, the materials used to make the final product are usually expensive, while the prototype raw material is made from something cheap. However, its properties are usually identical to that of the final product. This difference in raw material could cause a change in the appearance and finishing of the final product. Also, the quantity of the final product and prototypes made are always different. Normally, manufacturers make the product prototypes in low volume as they only need them for the production process. However, they make the final products in large batches for several reasons. One, the manufacturing process might be a complex one. Hence, they can’t afford to make the product in small volumes like the prototype. Also, producing the final product in batches will help save time and money.Prototype Development Phases
As mentioned earlier, there are three general phases involved in the product prototype development process. They are:1. Alpha Phase
This phase of prototype manufacturing develops prototypes that answer two questions:- How will the part look and feel?
- Will it work?
2. Beta Phase
This phase builds on clients’ feedback and stakeholders in the alpha phase to make even more sophisticated prototypes. In this stage, the products are inching closer to the final product in terms of the appearance of functionality. The prototypes also undergo extensive testing in this stage. The two prototypes produced in this phase are the engineering and production prototypes.
The engineering prototype is an upgrade to the proof of concept prototype in the alpha phase. It aims to achieve a visual, manufacturable, and functional imitation of the final product. Due to the feedback gotten previously, this prototype has even more sophistication made to it. The machinists use more complex manufacturing methods such as injection molding and sheet metal fabrication in this stage. This is to make it imitate the final product as much as possible. The machinist uses good-grade materials to make this prototype.
3. Pilot Phase
This phase is where the machinists make the final/pilot prototype. It is the first product as this is exactly how other part units will look like, provided there are no further problems. The only reason the machinists consider it a prototype is because it still needs to get some certifications. Some changes could still be made here, such as changing the production method (such as injection molding and CNC machining) used to make some metal and plastic parts. After any final changes, the machinists send the pilot prototype out to independent review committees for certification. After they’ve obtained these certifications, production can finally commence in the commercial phase. While some other machinists might use different terms like proof of concept (POC) and minimum viable product (MVP), these three terms are roughly universal for prototype development.Common Prototype Development Mistakes
Many new-timers in the industry tend to have some misconceptions about the prototype development stage, which can cause many problems with the final product. Examples of such mistakes include:- Not seeking expert considerations on how to progress through each phase of the prototype development.
- Failing to make an accurate estimation of the cost
- Not getting enough user feedback. User feedback is very vital for the success of the process.
- Trying to fit the prototype development process into a fixed time frame. The length of this process depends on the sophistication of the part.