From Prototype to Production: All You Need To Know

The development phase of every product in manufacturing passes through different stages. It starts with prototypes and then ends at final production.

The process involves various stages, and some considerations are important during the journey from prototype to production.

This guide features the entire process, so let's read!

Why Do You Need a Prototype Before Production?

Prototypes are very crucial in the development cycle because they lay the foundation of the manufacturing process. Some of the reasons why you need a prototype are as follows:

• You can test the design and its features. In case you need added features, you can have them.
• The performance of the design can be tested.
• If there are any errors and defects, they can be fixed before production.
• It gives a chance to closely review the design and components.

Steps from Prototype to Production Process

The steps involved in the prototype to the process of production are discussed in detail below:

Creation of the Digital Prototype Model

The process starts by creating a digital model of the component, which allows the concept to be turned into a real product. The stages involved in the creation of digital models are as follows:

• It starts with conceptual prototyping, where you communicate your ideas and consider the same concepts. It is a very cost-effective stage and you can communicate the ideas you have in the form of sketching.
• Once the conceptual prototyping has taken place, a prototype concept is created. A design is consistently made and tested before the high-volume production is done.
• The time required by prototype creation is based on the stage of prototyping you may be in; the sooner your design gets approved, the earlier production will start.

Product Testing and Market Analysis

Once the prototype is ready, its accessibility is very important to gauge before it is moved towards mass production and essential stages; it involves the following:

• The product’s demand needs to be tested, and the best way to do this is through crowdfunding projects.
• The tooling stage is then done, which involves converting the prototype in the form of a digital product to the actual physical product. The actual physical product is a type of sample. This sample helps in the assessment of the functionality of the product, and if needed modifications can be made before mass production starts.
• Once you have the physical prototype, you can modify it and improve its quality by eliminating the errors in the design.

Start with Low-Volume Production

Once you are sure of the design and performance of the prototypes, and you can vouch that they meet the aesthetics, functions, and standards you are looking forward to, then you have to move ahead with low-volume production.

Low-volume production means you will be manufacturing the product in small batches of around 50 to a couple of thousands of pieces so that you can meet the market demands.

• You have to start with the preparation of documents, which include 3D files; RPD, which has the features, value, and purpose of the product; details on the material and color; and an NDA agreement, which has confidential details. Also, include the cost of the material bill and final review of the prototype.
• The lead time for small-batch production should be less if you are outsourcing your production. The complexity of products will determine the time for manufacturing the parts.
• The transition of product from prototyping to manufacturing will be based on the budget of manufacturing too. You can have low-volume manufacturing initially with your given budget, and later on, you can arrange adequate resources to develop the molds and use the right material for your projects.

Practical Tips for Accelerating from Prototype to Mass Production

In order to accelerate the process of prototyping to mass production, some of the tips that may be helpful are as follows:

Select a Reliable Manufacturer

You must get in touch with a reliable manufacturer with sufficient experience. Ensure consideration of cost, quality, timeline, and material availability when selecting the manufacturer.

Carry out research on the manufacturers so that you can have multiple options to compare and choose.

Seek a Proof of Concept

A product is never considered ready unless it is reviewed, and make sure to discuss this with your manufacturer.

It will ensure that your product will be available to meet the demands in the future with the availability of methods involved in manufacturing followed by material requirements.

Opting for Appropriate Process and Materials

It is important that you choose an adequate process of manufacturing and also materials that are suitable for your product.

You have to assess each process and material, keeping in mind their pros as well as cons. Moreover, factors like budget, material type, and lead time are also crucial to be analyzed.

The quality of the material will have an impact on the cost of the project as well as quality. Hence, when choosing it, make sure to examine its mechanical properties, cost, and availability.

Create a Working Prototype

It is very crucial to test the design before heading to the stage of production. Hence, you must develop a working prototype and test its performance, design, and functionality.

In cases where modifications are required, make sure to address them, and look forward to improving your designs.

Inspect the Quality

Testing the prototype is very crucial to making it head toward the stage of production. You have to assess its quality in every way, be it design, features, or performance.

In case you detect any flaws, they can be rectified timely. Different tests can be performed to assess the quality of the prototype.

What to Avoid from Prototyping to Mass Production?

There are some mistakes that you should avoid in the journey from prototype to final product; these are as follows:

• One of the biggest mistakes to avoid is manufacturing the product before completing the design stage. It will end up costing a lot when you need to change your design later on. Sometimes, you even have to discard the tools or molds that you have made.
• Before the product manufacturing is approved, it is important that the manufacturer understands the design and concept in detail and reviews each and every aspect of the design. Unclear ideas may lead to a disaster.
• It is very important to have a plan for testing the performance of the component. Hence, the process must be slowed down rather than rushed into manufacturing. Proper testing and reviews must be made beforehand.

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DEK is your reliable manufacturer for validating your prototypes. We have a team of skilled professionals who ensure that the products you manufacture are of high quality at each stage.

We have a team that has expert knowledge of processes like 3D printing, injection molding, and CNC machining, followed by the capability to deal with high as well as low production.

So, share your design with us today.

Conclusion

The process of prototyping to production is very crucial for the success of the components manufactured and used in different applications.

Hence, when it comes to manufacturing, the products in each and every stage from start to end need to be focused very carefully.

FAQs

How much does prototyping cost?

The cost of prototyping varies based on the complexity of the design, the chosen process, and material. Hence, it will change based on what you choose.

What are the different types of prototyping?

The types of prototyping consist of rapid prototyping, extreme prototyping, incremental prototyping, and evolutionary prototyping.

Which steps are used to drive from prototype to production?

The process of prototype to production consists of creating prototypes, approving them, low-volume production, and lastly, final mass production.

What is the next step after making a prototype?

After the prototype has been made, the next stage is optimization and testing.

How do you mass produce a product or part?

To produce the products and parts in a mass volume, division of labor and automated manufacturing processes are opted.