Guide to Types of Prototypes and Prototyping Techniques

What is a Prototype?

Prototypes are versions of a product or part manufactured as an experimental representation for the purpose of testing, evaluating, and validating a design’s functionality and producibility. This interactive version of the prototype allows the manufacturer to engage with and understand the pros and cons of mass-producing the particular part or product. It helps to understand the functionality of this product and its amenable flaws before investing in its production in mass.

Thus, if a product or component prototype had complex designs initially, it can be simplified in subsequent productions. Prototypes show what the final product will be like and allow the manufacturer to effect changes and improvements on them before concluding manufacturing. It also allows for an initial evaluation of the shape, ergonomics, and size of a component as well as its functionality.

Types of Prototypes

Prototypes can take many different shapes and levels of realism in the field of design thinking. Each sort of prototype has a special purpose and provides distinct advantages during the engineering design process. Types of prototypes can depend on the phase of the project as well as the expertise of the design team. Let’s explore the types of prototypes.

Sketches and Diagrams

Sketches and layouts are 2D drawings that demonstrate the concept of a design from various perspectives. These diagrams are used to convey the idea in its entirety. They are also used to communicate the material or information flow, and system architecture, as well as comparisons of several alternatives.

Digital and Computational Models

Digital and computational models are computer-based or mathematical illustrations of the design concept that convey its performance, optimization, or behavior. These models are useful in the exploration of the design space, analysis of trade-offs between varying parameters, as well as the simulation of outcomes under different scenarios.

Physical Prototypes

Physical prototypes are items or objects made to resemble the design in all aspects, including interaction, functionality, fabrication, and appearance. They are normally used to test user context, their interaction with the product design, users’ intention for it, product performance, its production process, and assembling possibility.

POC Proof of Concept Prototype

Proof of Concept prototype helps the producer evaluate the feasibility of a design concept as regards the part or product. It helps to test the basic functionality of a design concept as to how it answers the questions posed during the design process.

POC helps you check whether the product matches the expectations you had during the design process. It gives you a preliminary physical view of your digital creation and how it fulfilled your design dreams.

Functional Prototype

This type of prototype, as the name goes, helps to evaluate the functionality of a design for a component. Most times, the product is used for the purpose or the part fixed into the framework to test how it fits. Functional prototyping also helps you identify correctable flaws in the design and improve the satisfaction of the final user or client.

Form Study Prototype

Form study prototype helps to examine the shape and size of a particular product or component design before the final production. It also aids in the evaluation of the ergonomics and aesthetics of the design and material choice in physical form before the final execution.

User Experience Prototype

A user experience prototype tests the ability of the user to effortlessly utilize the product of a particular design. It evaluates the experience of the user and therefore is a test indicator that simulates the relationship between the product and the user.

Preproduction Prototype

These prototypes are more or less made from the same resources, procedures, dimensions, and instructions as the final product. The main purpose of preproduction prototypes is the validation of the production and packaging processes. You can also use them to examine and confirm the consistency and quality of the product while arranging the transition process. Preproduction prototypes also come in handy for making product regulations or marketing.

Why Do You Need to Make Prototypes?

Prototypes are testing equipment for different metrics and purposes. They help every designer to test the functionality, suitability, and durability of a product design physically and how it holds up when produced in mass. Here are some reasons why you need prototypes.

Evaluation of Usability

Making a prototype of a product helps you understand how it suits your design and also fits into the purpose of the entire product development process. A prototype gives you a realistic opinion of a product’s functionality and you can use it for the designed purpose.

Efficient Cost Analysis

Prototypes give a real cost point of view of a product design. With the physical representation of a product, you can deduce how cost-effective the entire process will be, thereby giving you an overview of how much the entire production process will cost.

Material Optimization

Prototypes give the manufacturer a chance to evaluate the impact of a chosen material on a product and how it fits the design and purpose. It also allows for several trials with different materials of varying costs to achieve the aims of the design.

Optimize Quality and Reduce Errors

For the best quality of a production process with little or no errors, you need to get a prototype of that product. With a prototype, you can point out errors and how they affect the end product and purpose. This helps you correct these errors and also match the needed quality as stated in the order or preliminary design.

Common Steps for the Prototyping Process

The prototyping process comprises a series of well-organized steps that culminate in a flawless representation of the design product. Here are the steps:

Design Objectives Identification

The first step is to identify the objectives or goals of the prototype design. Understanding the purpose of creating the part or product will aid in the effective design of the prototype. It’s best to research existing market trends when creating a product prototype and aim for a unique design while also identifying Key Performance Indicators (KPIs).

Create Digital Design

Once the objectives have been outlined, the next step is to create the digital design that will be made into the 3D model. You could also use low-fidelity prototypes to obtain a preferred design, such as using paper or cardboard to design a prototype model.

Making the Prototype

After the design, choose the preferred prototyping technique that suits the product design perfectly, such as 3D printing or CNC machining. The next step is to choose the materials that best fit the final product and the tools to execute the design plan. Once selected, create a prototype and prepare it for testing.

Evaluation and Validation

The created product prototypes are tested against all KPIs to assess their suitability for the desired end product. The evaluation is best done by the client or user, with the results thoroughly documented and implemented. At the same time, compare results with the initial objectives and review, correct, or refine as needed.

Then, continue refining and iterating according to the observed improvement statistics. Ensure the product prototype meets the objectives and satisfies any new targets set. Make sure the final evaluation before confirming the final production.

Prototyping Techniques and Tools

There are different prototyping methods and tools used to create the perfect prototype. The method used depends on the desired product prototype and the prototyping aim. Here are some prototyping techniques and tools:

Paper Prototyping

The use of paper is a low-fidelity prototyping process that involves making actual hand-drawn models of a design concept. It is a simple and economical technique to visualize concepts and gather input early in the design process. Designers can recreate the user experience by sketching screens, interfaces, or even full user flows on paper.

Digital Prototyping

Digital prototyping uses software tools to produce interactive and realistic illustrations of design concepts. As technology advances, various digital prototyping tools enable designers to construct dynamic interfaces, mimic user interactions, and test product functionality. These tools frequently include pre-built components, graphics, and interaction patterns, allowing designers to generate high-fidelity prototypes without needing to code. This type of prototyping offers a more realistic evaluation of the user experience and provides more elaborate insights into how the finished product will look and perform.

3D Printing

This form of prototyping is revolutionary in the manufacturing world. 3D printing helps producers and manufacturers build the perfect product prototype through the machining process of adding material to a sample. This technique involves replicating digital designs into tangible products, where all metrics can be evaluated. It allows for the production of complex shapes and different forms that are difficult to replicate with traditional manufacturing processes.

CNC Machining

CNC machining removes material from the solid base by turning operations or through milling to achieve prototypes with precision. The CNC prototyping is mostly of high precision as the method yields highly precise results, which realize the intricate designs and accurate dimensions for better evaluation and refining.

Challenges and Tips for Prototyping Process

The benefits of prototyping are numerous, but it comes with its challenges. Here are some prototyping challenges and tips.

Integration and Compatibility

Prototypes sometimes do not integrate with the design or are compatible with the objectives of the stakeholders. It’s best to plan for any inadequacies due to compatibility with the design team, as this would help address any integration challenges.

Time Constraint

The amount of time available for comprehensive prototyping may be restricted by strict project schedules. The best solution is to prioritize important features and concentrate on developing key prototypes for essential elements. Establish reasonable deadlines for prototyping and let stakeholders know how important this stage is.

Limited Available Resources

Resource allocation is a big challenge in prototyping, as tools, designers, and developers can strain resources. The product prototype produced will use materials and machinery set up for the entire production and may be wasted, as many corrections might be necessary. The best way to manage this challenge is to produce prototypes that are continuously usable. One-off prototypes cost more to produce and waste materials.

Different Ideas of the Stakeholders

Another challenge worth noting is the diverging ideas of the stakeholders involved. The deciding personnel may have misaligned expectations, which may affect the final product prototype and lead to multiple corrections. The best way to handle this challenge is to establish a proper communication channel before prototype production.

Prototype Examples in Various Industries

Prototyping can be used in various industries to achieve the ideal version of a product. Here are some prototype examples in various industries.

• Aerospace Industry: Prototyping is used in the aerospace industry to perfect designs for airbuses and spacecraft. For instance, it is used for aircraft part validation. Component evaluation is also conducted with the help of prototype design to check the suitability and durability of aircraft parts.
• Automotive Industry: The use of prototypes in the automotive industry helps to test parameters like the aerodynamics of a design or product. For example, an engine prototype can be produced to see if it fits with the initial objective and also fits into the vision for the vehicle.
• Healthcare: Medical devices like pacemakers and artificial implants or limbs are produced after prototype testing is conducted. Prototyping also helps with the production of surgical tools and imaging equipment.
• Industrial Equipment and Machinery: Equipment like pumps and valves undergo thorough prototyping before final production to help identify any potential errors that could be fatal. Conveyor system designs also undergo strict prototyping processes to ensure an impeccable final production.

How to Choose the Right Prototype?

The main aim of prototyping is to achieve the best version of the design. To achieve this, it is important to use the right prototype for the objective. Thus, how do you choose the right prototype for your product at a specific time?

• Know the Stage of Your Product Lifecycle: Consider the lifecycle stage of your product before selecting the prototype to use. The three stages of a product lifecycle are the early stage, growth stage, and maturity stage. Therefore, before moving from prototype to production, you should know which stage it’s in.
• Understand the What, Why, and How: Identify the need for a prototype before choosing a type, technique, or method. Gain insight into the current use of the product to assess the needed changes. Also, identify potential features and validate ideas for new changes.
• Define Prospective Outcomes from the Prototype: Always ensure validation of the customer’s need and evaluate the feasibility of solving technical issues to improve the product’s functionality and aesthetics.
• Align with Stakeholders: You can align expectations and obtain budget sanctions by showcasing them to stakeholders. The objective is to use testing and data backup to sell your proposal internally. It is especially relevant when management is unwilling to make adjustments and allocate funds for the requirement.