Why prototype? Reasons include testing designs and theories (e.g. will the product work as envisioned?) and considering alternatives. A design might look great on paper or even in a CAD file, but until you turn that virtual concept into a physical tangible reality, unknown variables can still exist--variables the could ultimately affect whether the product ever makes it to market.
At ThermoFab, we have deep experience in manufacturing prototypes, and, as a result, we want to share three tips to keep in mind when developing your prototype and readying it for full-blown production.
From Prototype to Production: 3 Tips
1. Work with an experienced designer, but don't overdesign. Remember, plastic is flexible. It moves. Keep in mind "tolerance stack-up": how many components are stacking up and mating together? Work with an industrial designer or engineer who has designed for plastic--not all designers have.
2. Use production-grade plastic. Production-grade plastics will provide a better idea of how the final product will look and work. It's definitely worth the investment to have a working prototype in the end, the key word being "working." At the same time, be mindful of where you can save dollars. For example, you might be able to use CNC machining and soft tooling to create the initial production pieces (and this will help you prove out your initial solid model CAD design), and then, in phase 2, you can go toward hard temperature controlled tooling which is ultimately the preferable option for seamless production runs. If the design is set--and time to market is critical--go with hard tooling to save time; your initial production pieces will serve as the "prototypes."
3. Keep the end phase in sight, even when you're in the prototype phase. We believe the prototype should provide a solid idea of what the final manufactured product will look like. To accomplish this, you need to think about your brand, colors, the location of labels, etc. now.
It also helps to work with a thermoforming company, like ThermoFab, that can handle everything in-house from product design all the way to production of your parts.
Case in Point
Paper to Prototype in Less than 8 Weeks!
Start-Up Partners with ThermoFab
Marc Horn, PhD, President of Prospect Biosystems, is a self-described "serial entrepreneur with more than 30 years experience in the bioanalytical instrumentation marketplace."
After having lived on the West Coast for the past eighteen years, Horn's new venture led him back East. Arriving in New Jersey at the company's headquarters in the NJIT Enterprise Development Center, Horn set out in earnest to test and refine the technology of their new product. "It all went amazingly fast and we proved out the solution in four months time," stated Horn. The company developed the EDGE (TM) 200 System as its "initial biomarker discovery platform used to accelerate drug discovery, development, and commercialization."
Challenge: Prospect Biosystems Knew the Inside, but Needed the Outside Too
Eager to start presenting their innovative instrument to the scientific community, Horn knew finishing the product and getting the enclosure right would be a significant undertaking prior to launch.
Having left all his West Coast contacts behind meant that Horn had to start from scratch to find a partner to develop the housing. Fortunately, several local contacts and new associates referred him to ThermoFab.
"Being in New Jersey, I wanted a company that was close by. After checking out their web site and seeing the scale, magnitude, and complexity of the products they produced, I got in the car with several people from my company and made the drive to Shirley, Mass., for a site visit," stated Horn.
Solution: Trip to Facility Seals the Deal
So what did Horn think of ThermoFab and how did the prototype process go? Read the rest of this customer story and see how ThermoFab turned notebook sketches into a prototype in less than eight weeks .