Fail fast, learn fast, succeed sooner. Prototyping is the iterative bridge between a digital model and a successful product. Choosing the right method for each stage of development saves time, money, and reveals critical insights about your design's form, fit, and function.
Match the Method to the Question
This guide helps you select the optimal prototyping technology based on what you need to learn.
Define your goals and build a phased plan from look-alike to works-like.
- The Four Prototyping Archetypes: Visual, Functional, User, and Pilot
- Building a Stage-Gate Prototyping Plan for Your Project
- Budgeting for Iteration: Allocating Resources for Multiple Rounds
- (Link to site-wide tag: Cost Reduction)
Create tangible models to evaluate aesthetics, ergonomics, and assembly.
- 3D Printing (SLA, Material Jetting): For high-detail, smooth-surface models that look like production parts.
- CNC Machining (Foam, Ureol): For large-format models, architectural mock-ups, and clay-like sculpting.
- Vacuum Casting (Urethane Resins): For small batches of models that simulate the look and feel of final injected plastics.
Test mechanics, strength, thermal response, and other real-world behaviors.
- CNC Machining (Production Materials): For parts that must bear load, withstand heat, or interface with existing hardware.
- 3D Printing (FDM, SLS, Metals): For testing complex mechanisms, custom jigs, or components under stress.
- Rapid Tooling & Low-Volume Molding: For producing 50-500 functional parts in end-use materials for field testing.
Design your part with the prototyping phase in mind to maximize learning.
- Designing Multi-Process Prototypes (e.g., 3D Printed Housing with CNC Insert)
- Creating "Testable" Features in Your CAD Model
- Using Prototypes for User Feedback and Investor Presentations
- (Link to site-wide tag: Basic Design)
Transition smoothly from validated prototype to manufacturing-ready design.
- Incorporating Prototype Feedback into Final DFM Changes
- When to Move from Prototype Tooling to Production Tooling
- Managing the Handoff: Documentation for Your Manufacturing Partner
- (Link to site-wide tag: Quote issue)
How to Use This Guide:
- Ask: "What is the single most important question I need this prototype to answer?"
- Map: Match your question to the primary goal in Section 1.
- Select: Choose the most suitable technology from Section 2 (for looks/feel) or Section 3 (for function).
- Design & Iterate: Apply tips from Section 4 and use feedback to refine your design.
A prototype is a question answered in plastic, metal, or resin. Start with a solid foundation by applying Basic Design principles to your prototype, and explore advanced functional integration with Complex Design.