Decide what the prototype must prove
Form, fit, function and appearance have different tolerances and different cost curves. A visual model can be printed overnight; a functional test part usually needs the real material and the real process.
- Visual or ergonomic model
- Fit and assembly check
- Functional or load-bearing test part
- Pre-production sample in the production process
Keep the production path open
Prototype in a process that shares constraints with the intended production process wherever you can. Otherwise a design that works as a printed part quietly becomes unmanufacturable when it moves to molding or casting.
Expect iteration and plan for it
Ask about revision turnaround before the first order. A supplier who returns a change in days is worth more than one who is cheaper per part and slower to respond.
What to look for in a supplier
- Fast quoting and short lead times
- Willing to review the model and flag manufacturability issues
- Access to the production process you intend to use later
- Clear handling of revisions
Certifications buyers often need
- ISO 9001 where documentation matters even at prototype stage
- Material certificates when the part will be tested to a standard
Questions to ask prospective manufacturers
- What would you change in this design to make it easier to manufacture?
- What is the turnaround for a revised part?
- Can you make this in the same process I plan to use in production?
- What does the same part cost at production quantity?
Frequently asked questions
- Should I prototype in the production process?
- When the design's risk is manufacturing risk, yes. When you are testing appearance or ergonomics, a faster and cheaper process is usually sufficient.
- How many prototype rounds are normal?
- Most parts settle in two or three rounds. Budgeting for a single round is what usually causes schedule slips.