Types of Prototypes in Product Development
When developing a new product, the terms prototype and proof of concept are often used interchangeably, but they refer to different stages in the design process. Understanding these stages can prevent confusion and ensure a smoother path from idea to full production.
Proof of Concept (PoC)
A proof of concept is the earliest version of a new product, whether it’s a new invention or an update to an existing design. The focus at this stage is functionality, not appearance. Proof-of-concept models are often rough, lacking visual appeal, but they establish whether the idea works.
Key points about PoC models:
-
Require little or no investment in tooling
-
Great candidates for 3D printing
-
Support early design visualization using CAD and simulation tools
-
Should undergo basic performance testing, since even one test model can provide valuable insights
💡 At this stage, computerized analysis is helpful, but real-world testing is irreplaceable.
Pre-Production Prototype
Often confused with a PoC, the pre-production prototype is the next step toward a market-ready product. This stage introduces manufacturing considerations and moves closer to the final design.
Important factors to consider:
-
Anticipated sales volume and production methods (molding, machining, casting)
-
Avoid investing heavily in permanent tooling—the design is still flexible
-
Perform performance testing and in-house pre-certification tests where possible to save time and money
HALT and FMEA
-
HALT (Highly Accelerated Life Testing): Increases stress until failure, helping identify weak points
-
FMEA (Failure Modes and Effects Analysis): Systematically evaluates potential failure risks and impacts
Production Prototype
At this stage, the design is much closer to final. Limited investment in non-permanent tooling may be worthwhile, and manufacturing methods should reflect expected production.
Key steps:
-
Use actual production methods where possible
-
Run short production tests
-
Conduct formal certification tests
-
Remain ready to adjust design based on test outcomes
Full Production
Here, the design is finalized and permanent tooling is in place. Before mass production begins, every department should confirm readiness.
Pre-Production Checklist
-
✅ All design changes completed and validated
-
✅ All drawings updated to print
-
✅ Parts evaluated for form, fit, and function
-
✅ Documentation finalized
-
✅ Packaging design approved; vendors ready
-
✅ Bills of materials complete
-
✅ Outsourced parts available and approved
-
✅ Assembly staff trained
-
✅ Quality control plans in place
-
✅ Vendor qualifications verified (with backup vendors for risk management)
-
✅ Export legalities and compliance addressed
-
✅ Final pricing established for off-the-shelf components
This checklist is not exhaustive, but it ensures all stakeholders are aligned before production runs begin.
Conclusion
From proof-of-concept models to full production, each prototype stage serves a unique purpose in reducing risk, validating design choices, and preparing for manufacturing. By carefully following each stage and documenting data, teams can accelerate development, minimize costly errors, and launch more reliable products.
Analytical Engineering Services, Inc.
Elko New Market, MN
www.aesmn.org