LECTURE 2:

PROTOTYPING

By Dr Sampa UnniKrishnan
Yateer Creative Solutions
[email protected], 8971442777
 WHAT WE WILL LEARN IN THIS TOPIC
1. Definition Of Prototyping
2. Application Of Prototyping In Different Industries
3. Different Categories Of Prototyping
4. Role Of Prototyping In Product Development
5. Product Designing And Prototyping
6. Prototyping In Tooling
7. Prototyping In Manufacturing
8. Materials For Prototyping
9. Prototyping Techniques/Tools And Rapid Prototyping
10. How To Choose Prototyping Tools For Your Application
PHASES OF PROTOTYPING

ALPHA BETA PILOT

Proof of Concept Fully The first Unit

Prototypes Functional to roll off the
Appearance Engineering assembly Line
Prototypes Prototypes Prototype
Working Pre-Production before
Prototypes Prototypes manufacturing
 PROTOTYPE IN MANUFACTURING:
PRODUCTION PROTOTYPE
AIM : To develop the manufacturing processes and techniques
required to produce the product
● In estimating material requirements and costs.
● In determining manufacturing time and personnel
requirements.
● To acquire funding, create budgets, and determine the final
cost of the product, plan for installation and field support.
● For Compliance Testing
● For checking reliability of the manufacturing process
DIFFERENCE BETWEEN PRODUCTION AND
ALPHA PROTOTYPE
Production Proto Alpha Proto
AIM Verify Design for Verify performance and
Product Manufacturing appearance of the
planned product
Material Final Product Material Could be different from
final product material
PRODUCTION PROTOTYPES HELP
ANSWERING THESE QUESTIONS
● Can the product be produced with existing machinery?
● Are adaptations necessary to manufacture the
product?
● Is it necessary to purchase new machinery?
● If any adaptations to current machinery, or new
machinery, is needed for production.
 PROTOTYPE IN ASSEMBLY LINE
● To determine if the fit of the parts is correct. This saves
money in time lost to rework and the cost of wasted
materials.
● To determine if the materials used are durable and capable of
withstanding the wear and tear of use.
● To receive feedback from clients, distributors, and customers.
● Customer research and feedback helps to create customer
satisfaction and provide you with confidence in the product’s
marketability
EXAMPLE OF CARD SWIPING MACHINE

Working prototype
does not fit the
form and size of
the visual
prototype created
by product
designers.

WORKING PROTOTYPE VISUAL PROTOTYPE

DESIGN FOR MANUFACTURING

PCB board (top picture)

along with its
enclosure(extreme right
picture)was engineered
to fit the visual prototype
ASSEMBLY PROTOTYPE

Prototype was made

to test the assembly
of all the parts
together after the
DFM exercize.
FINAL ENGINEERING PROTOTYPE
Final Engineering
prototype of the
product was made
which satisfied the
functionality as well
as form and size.
It was ready for
replication.
 PRODUCT DESIGN AND PROTOTYPING
Questions to the Product Designing Students:

1. What is your new product design?

2. Will your design satisfy all the features of the intended

product?How do you know?

3. Would you like to make a prototype of your newly

designed product?
WHY DO PRODUCT DESIGNERS USUALLY
DROP THE IDEA OF MAKING PROTOTYPE?

● Much effort is required to make a prototype

● It is time consuming. Need to deliver the design in a
short amount of time.
First, You need to understand why it is an essential
component of the product design process to create
prototypes. Then, you can see how we could make
prototyping process fast.
1. PROTOTYPES IMPROVE THE OVERALL
UNDERSTANDING OF THE DESIGN

● To Communicate Your design To Your Design Team

● To show how your design satisfies the functions and
features of the final product
● To show how the design is perfect for our target
audience.
2. PROTOTYPING MINIMIZE DESIGN
ERRORS
● You create the final
● If a product is near product of a truck,
completion, making any ● Then you realize that
drastic changes would the back seats are too
create more work and short
increase the budget ● Now you need to
change the structure of
the vehicle, prolonging
the deadline.
IN THE LAST EXAMPLE

● The top frame of DipJar evolve from an extremely difficult part to

mold on the left to the final production part on the right.
● Many features were optimized through prototyping, including: wall
thicknesses, drafts, rounds, screw bosses, heat stakes, optics,
finish texture, and structural integrity.
3. PROTOTYPES ALLOW FOR USER TESTING

● Every product has a target

audience, and at the end
of the day, the audience is
going to have the final
say.
● Prototypes allow for user
testing, which provides An IDEO team observing a
designers with valuable blind user testing a prototype.
feedback about their
FOR AUTONOMOUS CAR PROJECTS AT TEAGUE
Background: They have found it to be indispensable to use
physical prototypes to test our designs with users

Physical prototypes create a great stage for user testing. They

also require a lot of work that slows the iterative process.
VIRTUAL REALITY WAS USED AS
PROTOTYPE

According to the demand of users,

Testing User Concepts like privacy glass in AV
Experience virtually mode (left) or a third person view
screen (right) was easy to test
 A SCHOOL TEACHER’S INVENTION
● A simple and elegant fashion
design solution that solves a
big problem: Losing your
rings!
● Designed, prototyped, and
manufactured by Mako
Design + Invent.
● This was her first invention, ● Now she has buyers from all
and her first time taking a over the world, and is scaling
product to market to test up by working with
usability, and she rocked it! wholesalers and distributors.
4. PROTOTYPES IMPROVE TEAM
COMMUNICATION
● When you have a physical
product, it’s easier to
provide feedback and see
whether the product has a
specific limitation.
● Prototypes ensure that the
product you’re creating is
serving its purpose.
 STORY OF A DESIGNER JOINING TEAM
NEWLY IN A COMPANY
● In SAP Design and Co-innovation Center in Korea, the
designer got an opportunity to develop new design of furniture
for workspace.
● Team decided to codesign the furniture together and they
decided to make cardboard prototype of their designs.
● Through the hands-on prototyping and experimentation, he
learned that the prototyping session was not just making
cardboard furniture, but understanding other colleagues’ views
and behavior.
● Having created the prototypes, he could collect a lot of
feedback from colleagues.
● After several iteration loops, initial ideas were refined to the
final design plan.
● As a new hire at that time, he got the opportunity to get to
know other team members in a natural way while engaging
and interacting with them to build cardboard furniture.
● From his experience, prototyping can help a team build
rapport between members by doing something together
rather than just thinking.
 5. PROTOTYPE ATTRACTS INVESTORS
● It’s normal for a product to hit financial patches and require
an expanded budget.
● If a product needs further investment, having a prototype is
an attractive feature.
● Investors aren’t interested in spending money on a design
that may work once it’s produced. They want to see the
product in its physical form.
WATCH THE VIDEO OF AN INVENTOR

● Having the expertise to

build and consult on a
fully functional prototype
will provide your
audience with something
tangible to get behind, so
you’re not leaving
anything up to their
imagination.
HOME SAFETY INVENTION IDEA THAT EARNED
$100,000 INVESTMENT ON TV PITCH
● Earned two investors on Dragon’s Den.
● Jon built up a home-built rough prototype of his invention
which would power a house through the use of your car’s
engine idle power.
● The key was for it to be waterproof, be reliable, incorporate
modern but sporty design, and be manufacturable at scale.
● This was Jon’s first invention idea, and already has become
a booming success both with funding appearances on TV.
6. PROTOTYPES MEASURE ACCEPTABLE
TOLERANCE LEVELS
This is your chance to decide if any design adjustments can
make the production process more economical
7. PROTOTYPING HELPS MODIFY YOUR
TOOLING FOR MANUFACTURING

Once you’ve done your prototype, you may realise

that you can make efficiencies by adjusting your
tooling and equipment.
PROTOTYPING BY PRODUCT DESIGNERS

Ask 3 questions:
1. Purpose:Why are you making a prototype?
2. Tools: What is the ideal material and method of
prototype
3. Design for prototyping: What design will satisfy
the purpose of prototyping and method of
prototyping?
WHY ARE YOU MAKING YOUR PROTOTYPE?

Getting Ready
to manufacture

Simple
Visualization

Functionality
Of The
ProducT
QUESTIONS TO ASK DURING THE EARLY
STAGES AS YOU VALIDATE YOUR CONCEPT
1. What problem does your idea solve?

2. How are users solving this problem currently?

3. Can your target market think of another product that does

something similar?

4. How have previous solutions failed?

1. Do users understand what this product or service does?

2. How do users feel about the product or service?

3. Who is your competition?

4. What is the app/site for and what can users do there?

5. Does your target market have a need for this product?

6. What devices do users imagine themselves using when they

interact with this product?

7. What scenarios can they picture themselves using it in?

FOCUS ON THESE QUESTIONS AT THE LAST
STAGE TO SOLVE ANY USABILITY ISSUES
1. Does the prototype do what it’s supposed to?

2. Do users think the product’s design matches its purpose?

3. What’s the first thing users would want to do on this product?

Can they do that?

4. When they explore the product, do they become confused at

any point?
1. Are there any features they completely ignore?

2. Can users find what they’re looking for?

3. Does your target market feel like this product was designed for

them?

4. What, if anything, would make your users want to use this

product frequently?

5. How likely or unlikely would they be to recommend the finished

product to a friend?
DO YOU DESIGN FOR PROTOTYPE OR
YOU PROTOTYPE YOUR DESIGN?
Depends on which phase of product development you are at:
Rule Of Thumb:
You design for prototype, when you are at early stage of
product development of proving concept, making it work and
making it functional.

You prototype your design when you are developing the

product design for manufacturing
WHICH PROTOTYPE WILL YOU USE FOR YOUR PROJECT?
SOLUTION ENGAGEMENT FUNDING
IDEA PROTO
PROTO PROTO PROTO

TIME A DAY A WEEK A MONTH A QUARTER

Questions What is it? Could it solve a Can we build Can we get
problem/create buying-in and funding to build
something new excitement? it?
and valuable?

FOCUS EXPLANATION FUNCTIONALITY VISUALIZATION FEASIBILITY

Techniques Written ideas, Simple mock up, Limited function Functional and
Sketches, Cardboard model prototype, aesthetic
Workflow Simple video, looked
diagram 3D printed model prototype
FURTHER READING REFERENCES
Novice designers' use of prototypes in engineering design,
MichaelDeiningerShanna R.DalyKathleen H.SienkoJennifer
C.Lee, Design Studies,Vol 51, July 2017, Pages 25-65
FIDELITY CHANGES WITH TIME IN A PRODUCT
DEVELOPMENT PROCESS

very close to the finished product

static design diagram, looks more like a

prototype
outline structures and
layouts
First concept without details
MEANING OF FIDELITY

The degree of As you understand the design and the

exactness with functionality of the target product
which through experiment and validation, you
something is
copied or move from low fidelity prototype
reproduced. towards high fidelity prototype.
How detailed
and polished is You can communicate design of your
the prototype? target product to your client through
high fidelity prototype
EXAMPLES OF LOW FIDELITY PROTOTYPES
● Storyboarding.
● Card Board Prototypes
● 3D design sketch for visual prototypes
● Paper prototype
● Lego prototype
EXAMPLES OF HIGH FIDELITY PROTOTYPES
● A 3D plastic model with movable parts (allowing users to
manipulate and interact with a device in the same manner
as the final design) is high-fi in comparison to, say, a
wooden block.
● High Fidelity Prototypes give a real experience of the
product.
ILLUSTRATION
GPS DONGLE FOR SLR CAMERA

HIGH FIDELITY

3D printed

LOW FIDELITY
DEVELOPMENT OF A MECHATRONIC
PADLOCK
● 4 physical prototypes at
varying fidelity were
fabricated.
● 66 interviews with
users were conducted.
● Users were presented
with 1 of the 4
prototypes.
● Fidelity of prototypes
affects users’ feedback.
 PROTOTYPING TOOLS USED

For more concrete evaluations of design solutions, prototypes of

higher fidelity can be more suitable
PROS OF LOW-FIDELITY PROTOTYPING
● Quick and inexpensive.
● Possible to make instant changes and test new iterations.
● Disposable/throw-away.
● Enables the designer to gain an overall view of the
product using minimal time and effort.
● Regardless of ability and experience, we are able to
produce versions of products in order to test users or
canvas the opinions of stakeholders.
● Encourages and fosters design thinking.
CONS OF LOW-FIDELITY PROTOTYPING

● An inherent lack of realism,simple early versions

of a product may lack validity.
● Depending on your product, the production of
low-fidelity prototypes may not be appropriate for
your intended users.
PROS OF HIGH-FIDELITY PROTOTYPING
● Engaging: the stakeholders can instantly see their vision
realised and will be able to judge how well it meets their
expectations, wants and needs.
● User testing involving high-fi prototypes will allow the
evaluators to gather information with a high level of
validity and applicability.
● The closer the prototype is to the finished product, the
more confidence the design team will have in how people
will respond to, interact with and perceive the design.
CONS OF HIGH-FIDELITY PROTOTYPING

● They generally take much longer time to produce

● After devoting hours and hours of time producing an
accurate model of how a product will appear and
behave, designers are often loathed to make changes.
● Software prototypes may give test users a false
impression of how good the finished article may be.
● Making changes to prototypes can take a long time,
thus delaying the entire project in the process.
MATERIALS FOR PROTOTYPING
● even if you have a functioning product, the way that
that is built or designed is crucial to how the product
will feel in the hands of the consumer.
● what is also important is envisioning the quality of
the product.
● a good engineer will typically know based off the
nature of the idea of the product which materials will
work best for what the product is supposed to do
Prototyping Techniques/Tools

CATEGORY OF PROTOTYPE PROTOTYPING TOOLS

PROOF OF CONCEPT,LOOKS BASIC MODEL MAKING
LIKE PROTOTYPE FABRICATION
3D PRINTING
FUNCTIONAL PROTOTYPE FABRICATION
3D PRINTING
MACHINING
ENGINEERING PROTOTYPES 3D PRINTING
MACHINING
COMPARISON OF TOOLS
COST LEAD TIME MATERIALS

1 BASIC MODEL ● Clay, Cardboard, Lego,

MAKING $ FEW HOURS foam

2 FABRICATION FEW HOURS ● Sheet metal, aluminium

$$ extrusion, plastic, wood
TO DAYS

3 MACHINING FEW DAYS ● Metals, plastics,

$$$$ composites
TO WEEKS

4 3D PRINTING $$$ FEW HOURS ● Plastics, metals

TO A DAY
 ACCU
PROS CONS
RACY
Easy to access Low precision
1 BASIC MODEL
●

MAKING Materials and tools, ● High skill required

less time

High skill
2 FABRICATION
●
Less time, easy to
revise prototype ● Many tools

High investment
3 MACHINING Different materials,
●

complex shapes ● Time consuming

3D Test of true form, fit ● Post processing

4 and function, complex cost
PRINTING ●
shapes creation
COULD INJECTION MOLDING BE USED
AS PROTOTYPING TECHNIQUE?

YES. When the prototypes are made in the pilot phase,

to test the market and to get the feedback from end
users, many times, the numbers of prototypes made are
in tens of thousands. If the design and the material
demands it to be plastic, injection molding could be used
WHEN DO WE PROTOTYPE IN TOOLING
● Engineers need to demonstrate how a new design will
perform as part of management approval for investment
into production.
● Regulatory requirements: Testing of products from
representative materials and processes that correspond
to those intended
● In above cases, one may use injection molding as the
production technique. Making prototype tool for quick
production may be cost-effective.
PROTOTYPE TOOLING IS ALSO KNOWN
AS RAPID TOOLING

FEATURES:

● Making molds in smaller quantities (1000-10,000)

● Simple cavity molds
● Use of Aluminium or SS as the material for the mold
which are easy to machine (fast and cost effective)
HOW DO YOU DECIDE
YOUR PROTOTYPING
TOOL?
Q1. WHAT IS THE AIM OF PROTOTYPING?

Want to talk to a Want to Want to see Want to sell

stakeholder validate or the demand product and
about your patent your of your start
Design? design? product? production?
Q2. WHO ARE YOUR STAKEHOLDER(S)?

Another Your own

An An end
company company
Investor? user?
leader? leaders?
Q3. HOW MANY PROTOTYPES DO YOU
WANT TO MAKE ?

Upto 10 nos Upto 100 -1000 nos

1 no at a time Upto 50 nos at at a time to test the
at a time to
to test design test working of a time to test market demand
or prove the the usability of and get customer
different
concept ? the prototype? feedback?
functions?
Q4. WHAT DESIGN DO YOU WANT TO
PROTOTYPE? Designs
for Laser
cut
Is it a simple
Is it a complicated
design with
design with internal
regular
small holes,
geometrical
organic geometry
structures?
with many curves?

Design also tells about the

dimension and complexity of
making the prototype
Q5. WHAT TIME FRAME DO YOU WANT TO
BUILD YOUR PROTOTYPE?

A 90-day deadline can act as a litmus test for

your idea: If you can’t build and test a minimum
viable product within 90 days, your idea is too big
and unwieldy.
EXAMPLE
AIM STAKEH NUMBER DESIGN TIME TOOL
OLDER

Test the End User 10000 Simple 3 Injection

demand rectangular months molding
of the with curved
product edges
Concept Investor 1 no of 5 Organic 1 week 3D
Test different Shape printing
designs
MACHINING Vs MOLDING
Machining Injection Molding

Moq Low High

Cost Lower Higher

Design Freedom High Low

Consistency In Quality Higher Lower

Lead Time Low High

Alterations High Low

 SUGGEST PROTOTYPING TECHNIQUES FOR
THE FOLLOWING

Lounge Chair Frame

Electric Kettle Base
Product Size: 750.8mm * 666.6mm * 571.9mm Part Size: 185.5mm * 198.3mm * 55mm
Quantity: 1 complete set, 7 components per set Quantity: 510
Delivery Lead Time: 10 calendar days
Delivery Lead Time: 15 calendar days
Purpose: Quick New Design test Purpose: to test the working of the base first
QUESTIONS INDUSTRY ASK AT EVERY
STAGE OF PRODUCT DEVELOPMENT
CYCLE

FASTER PRODUCT SHORTER DESIGN

INTRODUCTION TO CYCLE
MARKET

A SENSE OF
AN URGE TO FAIL FAST RAPIDNESS
HOW DO YOU MAKE THE PROCESS OF
PROTOTYPING RAPID?

REDUCE THE
REDUCE THE TIME OF
DESIGN PROCESS TOOLING
REDUCE THE DESIGN PROCESS

1. No Need Of Thinking On Design For Machinability

2. No Need Of Thinking On Waste Of Material During
Designing
3. Design Could Involve Simply Complex Geometries
4. No Need Of Thinking Of Special Tooling To Make Designs
With Small Cavities
5. You Could Simply Design To Convey Your Idea And
Features For Functionality
REDUCE THE TOOLING PROCESS

1. One Machine Could Build Up The Complete Design

With Different Parts And Complications
2. Choice Of The Right Machine And Material As Your
Tool