How To Develop A Product Design Prototype In 6 Steps

What is a Product Design Prototype?

A prototype is the physical manifestation of an idea, an important step in product management. It takes the conceptual product and brings it into the real world. There are various ways that a prototype can be created, from a quick sketch to something three-dimensional, depending on the time and effort you want to spend. Paper sketches are the simplest type of product prototype, but you can also make a digital prototype. 

These mockups can help further the design, materialize your product vision, and get feedback from the engineering team. Of course, you can make physical prototypes as well. There are four types of product prototypes. 

• High-fidelity user prototypes test usability
• Live data prototypes test behavior with data
• Low-fidelity user prototypes test the value proposition
• Feasibility prototypes test technical limitations

A product prototype can even go through many stages, from a rough to a more functional, almost complete version. It’s through these exercises that design and engineering departments communicate and develop the idea into a working product.

The Different Types of Prototypes in Product Design

You can classify prototypes into four broad categories based on their function and complexity: 

Visual Prototype

The visual prototype is meant to showcase the size and shape of the final product. It doesn’t include the product's functionality, materials, or mass; rather, it simply represents its dimensions. 

A block of wood shaped in the form of the final product is a “visual prototype,” as is a digital model made in 3D rendering software.

Proof of Concept

This is a rudimentary model meant to demonstrate the functions and feasibility of the idea, that is, to prove that the concept can work. You’ll usually use the materials available to create this prototype. It doesn’t have to look, feel, or even work as the final result; it simply has to show that the idea is viable.

The original design for the Super Soaker is a great example of a “proof of concept” prototype. Instead of fancy machined parts, it’s made from PVC pipes and an empty Coke bottle.

Presentation Prototype

As the name suggests, this is a presentation-ready version of the product. It is functional and has the same appearance as the product. You can show this prototype to investors, manufacturers, and prospective customers to give them an idea of the final result. 

This prototype is usually made from custom materials and manufacturing techniques. You can see examples of presentation prototypes in concept cars created by car manufacturers. Since these are usually meant for demonstration rather than production, these cars often use expensive materials and boutique manufacturing techniques.

Pre-production Prototype

This is a modified version of the presentation prototype. It has the same functionality but is built using production-ready materials and methods. Manufacturers often examine the pre-production prototype to determine how to mass-produce the product. 

Each of these prototypes builds on the former. You don’t have to go through all four stages, of course. You might go from a proof of concept built from duct tape and paper to a production-ready prototype.

What is the Purpose of a Product Design Prototype?

Creating a prototype can be an important early step toward ensuring a successful production process because it can provide you with key information about your idea for a product. Here are some benefits of using a prototype in your product design process: 

Tests Your Product's Functionality 

Building a model of your proposed idea can help you determine whether your product functions as intended. After testing your product with a prototype, you can determine whether it works well enough to invest more time and money. Testing your product can also help you adjust to ensure optimal performance and eventual customer satisfaction. 

Saves Money Before Production 

Creating one or two prototypes is typically less expensive than mass-producing a product without testing it first. This is because a prototype allows you to perfect your product's design before spending the money to produce it and potentially recalling it if defects are present. You can also use a prototype to ensure the production process is economically viable. 

Allows You To Demonstrate Your Product To Investors 

A product prototype can also help you show investors what your product aims to accomplish and how well it works. Demonstrating your product with a prototype also allows you to answer investors' questions about your product. Prototypes can help convince investors that your product is useful and worth investment. 

Determines Your Product's Usefulness 

Another effective method of creating a product is allowing select members of your intended audience to use your prototype. This can help you determine whether they believe the product is useful. 

You can gather their feedback to learn more about what they like and what might require improvement. With this feedback, you can create an even more useful prototype or advance toward mass-producing your product. 

Highlights The Proper Materials To Use 

When you generate an idea for a product, you might determine the specific materials you require and an outline of your eventual product's shape. With a prototype, you can then take your original idea and learn how to create a better product at a lower cost. For example, your prototype might help you determine that changing the shape or fastening parts together differently can make your product sturdier than you believed possible with your original idea. 

Helps You Coherently Discuss Your Product 

When you speak to others, such as:

• Investors
• Manufacturers
• Distributors

They might have specific questions about your product, such as its dimension, weight, mobility, and other aspects. 

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How to Develop a Product Design Prototype in 6 Steps

1. Investigate the Market for Product Design Insights and Flaws 

Before launching into product design, scope out the competitive landscape. 

• Who are your competitors? 
• What are their strengths? 
• What are their weaknesses? 
• What does the user feedback say about their products? 
• What can you improve? 

Answering these questions will help you create a better design. Consider purchasing competitor products and disassembling them. 

• Look at how they work. 
• What solutions do they use? 
• What do you like? 
• What don’t you like? 
• Make sure to get feedback from actual customers.

Conduct surveys, analyze your results, and, in the end, create what your users dream about. 

2. Create an Initial Product Design Sketch 

Once you’ve done your research and have a solid idea of what you want to create, it’s time to get your ideas down on paper. The physical attributes of your product are one of the main selling points it will have.

Be sure to create the perfect balance between aesthetically pleasing and functional. Always gather feedback, listen to multiple perspectives, and modify accordingly. Here’s where putting your ideas down on paper will come in handy. It doesn’t take much effort and gives a good idea of what you want to create. 

3. Make a Digital Product Design Sketch 

Once you have your initial prototype on paper, it’s time to turn it into a virtual sketch. You can use many tools to make 2D and 3D renders of your hardware product. One of the most famous ones is AutoCAD. Further down the road, you can use other tools to create an even better model.

If you are not skilled in such programs or don’t bode well with technology, you can always get a graphic designer's help. Another option is to work with prototype manufacturing companies, and you can skip learning how to make a prototype.  

4. Build the Product Design Prototype 

Once you figure out what you want, you can choose from many ways to make a prototype. Here are a couple of prototype manufacturing options: 

• Build it Yourself: If you are skilled, it is not impossible; you can do it yourself. A 3D printer might do the trick. You’ll learn about the manufacturing process and maybe even develop better solutions. Plus, you’ll get to save your funds for the future. 
• Hire an Engineer or a Professional Prototype Designer: The pros know what they do. They do it for a living and have more efficient ways of bringing your idea to life. Building it yourself is a little more costly, but you will probably get some amazing improvement suggestions. 
• Advertise at an Industrial Design University: Students are always looking for projects to feature in their portfolio and some extra money in their student accounts, and they will require a smaller budget than a pro. This option is the most efficient when building an initial prototype. Future models may be built with more expensive materials, so catching your flaws earlier is better. 

5. Rebuild the Prototype to Perfection 

Your initial prototype is not going to be the final one. That’s why it’s a prototype! Don’t expect to build it and have it work perfectly (unless you’re that lucky). Be prepared to go through trial and error. Here are some questions you can ask yourself when testing a prototype: 

• What are 3 things you like about it? 
• What are 3 things you want to change? 
• Would you use it yourself? 
• Is this your best choice in the market? 
• Would you recommend it to friends and family?
  

These questions will help you organize and manage your solutions. Ultimately, you’ll have a product you’re proud of and that your customers will love. 

6. Costs of Prototyping 

Prototyping is a challenging process. It's an expensive and time-consuming phase, including all the material and labor costs. It’s especially costly since you won’t be making it in bulk. Each prototype will cost much more than your future cost per unit.

Different types of products require different costs in the prototyping stage. While learning about how to make a prototype, you should also learn about the costs that come with it. For example, here are some prototyping costs for soft goods to keep in mind: 

• Initial concept and mechanical design (up to $1000) 
• Technical drawings and specifications (up to $2000) 
• Around 3 rounds of prototypes (up to $1000/round) 
• Production tooling (up to $5000)
  

Prototyping costs can reach up to $35,000 for design products that require electronics or smart solutions. Prototyping of technology products is even more expensive, ranging anywhere from $25,000 to $60,000.

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12 Mistakes to Avoid When Creating a Product Design Prototype

1. Set Clear Objectives Before Building a Prototype

Prototypes can serve many purposes, so determine what you want to achieve before creating one. With a specific goal in mind, it’s easier to maintain direction – ending up with a focused prototype. Define clear objectives for your prototype from the beginning. Ask yourself questions such as: 

• Which specific aspects of this idea/solution do I want to test? 
• Who is my target audience? 
• What proof of concept (i.e. evidence that this is the solution customers need) do I have?
• What are the essential features or functionalities to include? 
• What’s my budget? 

2. Don’t Rush the Process

One common mistake is rushing the prototype development process, especially if you’re eager to quickly bring your idea to life. This can lead to a poorly designed or non-functional prototype, so don’t be afraid to seek advice if you need it.

3. Keep Prototypes Simple

Include only a few features in your initial prototype, making it overly complex and costly. Start with a basic version to test the core concept before adding more features.

4. Always Gather User Feedback

It is a significant mistake to gather feedback from potential users. Prototypes should be used to test and validate assumptions; user feedback is essential. 

5. Don’t Ignore Costs 

Have a budget and stick to it to avoid overlooking cost constraints when building your prototype. Creating a cost-effective prototype that doesn’t drain resources that could be better used elsewhere is essential. 

6. Focus on the MVP First

Instead of building a full-featured prototype, you should prioritize creating an impactful minimum viable product (MVP) – download our A-Z guide here. An MVP is a simplified version that demonstrates the core value of your idea, allowing for faster testing, iteration, and user/customer feedback. 

7. Test Your Assumptions

Remember that prototypes test assumptions about the market, user needs, and the idea’s viability. What is the hypothesis you’re trying to validate? 

8. Involve the Right Team Members

Building a prototype is a collaborative effort. Don’t try to do everything yourself ask experts for assistance if your team members lack the necessary skills. 

9. Conduct Competitive Analysis

Neglecting to research and analyze competitors can lead to a prototype that doesn’t address existing market gaps or offer a unique value proposition. 

10. Avoid Unrealistic Expectations 

Don’t expect your prototype to be perfect. It’s important to remember that prototypes are meant for learning and iteration. 

11. Consider Legal and Intellectual Property Issues Early On

First, protect your intellectual property. Please address legal and IP issues early on to avoid problems later. Check out our post on how to check the originality of your idea. 

12. Always Have a Backup Plan

Be prepared for the possibility that your initial prototype won’t work as expected. Having a backup plan and being open to pivoting is crucial if necessary. 

Can You Hire a Company to Create Your Prototype

You can hire a company to create a prototype, and in many cases, it’s a smart move. Product development firms offer specialized expertise, resources, and guidance that can significantly improve the quality and efficiency of your prototype development process.

Here’s how working with such a firm can benefit you:

Expert Product Design Guidance and Research

One key advantage of hiring a product development company is its ability to conduct and guide the necessary research. Research is crucial for understanding your target market, user needs, and technical feasibility. 

Many businesses need help gathering this information independently, which can lead to flawed designs or missed opportunities. A firm with access to advanced research tools ensures that your prototype is informed by real data and insights, setting a solid foundation for success.

Streamlined Design and Iteration

Once the research is complete, product development firms connect you with experienced designers and engineers who specialize in creating prototypes similar to your product. This expertise is vital for:

• Minimizing errors
• Streamlining the iteration process
• Reducing costs

A firm that handles research and design ensures a seamless transition from concept to prototype, saving you time and effort.

Guidance on Manufacturing

Beyond prototyping, a good product development firm can recommend manufacturers skilled in producing your product. This ensures that your design is production-ready and avoids costly missteps during manufacturing. By working with vetted manufacturers who follow best practices, you increase the likelihood of achieving a high-quality product while controlling costs.

End-to-End Support

The best product development firms provide expert guidance from initial research to final production. This comprehensive support helps you follow the right steps at the right time and provides a go-to resource for any questions or challenges. This level of involvement can make the difference between a smooth, successful process and one filled with roadblocks.

Why Hire a Firm?

Creating a prototype independently may seem cost-effective, but it often leads to trial-and-error processes that waste time and resources. By partnering with a product development firm, you gain access to specialized knowledge, professional networks, and a streamlined workflow that ensures your product development journey is efficient and effective.

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Schedule a call with us today to learn more!Imagine you've spent months working on a new product. You've researched, sketched, and even created a set of specifications. As you prepare to present your idea to stakeholders, you realize something needs to be added. You need a prototype. Prototypes help visualize your concept and communicate your vision to others. They are essential for just about every product design process. This article will help you understand how to create a product design prototype and why it is important.

NUMI has plenty of experience building product design prototypes. Our know-how can help you achieve your objectives, such as learning how to develop a product design prototype. With our support, you can create a valuable prototype that easily meets your goals and helps you navigate the product design process.