The Different Forms of Prototyping for Industrial Designers
- equipedesign
- Feb 22
- 5 min read
Updated: Mar 10
Prototyping is a critical stage in the design and development process, offering a tangible way to test ideas, gather feedback, and refine concepts before final production.
Essentially, prototyping is the process to ensure your project risk is decreasing as your time and financial cost is increasing.
One of the worst lines I have ever heard from a project manager is’ “Proceed on Risk” These 3 little words cost that business a year and who knows how much money.
Prototyping is simulating what your design and product could be without the extra time, money and commitment that full blown production tooling will lock you into, with reduced opportunity to change or optimise.
How do you test ‘prototyping’ to your hoped ‘production apples’ without ending up with ‘production watermelons’?
Different forms of prototyping cater to various needs and project stages, from early ideation to functional testing and even clinical trials and certification, depending on your market.
Understanding these forms and their applications can significantly enhance the efficiency and effectiveness of the development process.
1. Paper Prototyping
Paper prototyping is one of the simplest and most cost-effective methods. It involves creating hand-drawn or printed sketches to represent the user interface or product concept.
This form of prototyping is ideal for:
Early-stage brainstorming and ideation.
Testing basic design layouts and workflows.
Quickly iterating on concepts without significant resource investment.
By allowing rapid iteration and feedback, paper prototyping helps teams validate ideas before moving to more detailed prototypes.
2. Digital Prototyping
Digital prototypes are mock-ups created using 3D CAD software, CREO is my weapon of choice, along with SolidWorks.
These prototypes range from low-fidelity wireframes to high-fidelity, models that closely mimic the final product. Digital prototyping is especially useful for:
Visualizing user interfaces and user experiences (UI/UX).
Sharing high resolution concepts and design renderings with stakeholders for feedback.
To start to lock down product fit and form. What will the product look like and at a high level, how will it go together. Part lines between external components can start to be defined.
Advanced digital prototyping tools often include features for collaboration and user testing, streamlining the design process.
3. 3D Prototyping
3D prototyping involves creating three-dimensional models of physical products.
Back in my uni days before the prevalence of home based 3D Printing these were often hand built models. Carved with care and painted to look realistic.
Nowadays, with the development of home maker FDM 3D printers and using computer-aided design (CAD) software that are accessible to most people at very affordable cost, prototyping is available like never before.
This method is essential for:
Visualizing the physical form and dimensions of a product.
Testing design aesthetics and ergonomics.
Identifying potential manufacturing challenges early on.
3D prototyping bridges the gap between conceptual designs and functional models, ensuring that form and function align seamlessly.
4. Rapid Prototyping
Rapid prototyping leverages advanced manufacturing technologies, such as high fidelity 3D printing (SLA and SLS and their various evolutions), CNC machining, laser cutting, or vacuum casting to produce physical prototypes quickly.
This approach is ideal for:
Creating functional models for testing and validation.
Accelerating the iteration cycle by reducing production times.
Exploring complex designs that are difficult to create manually, especially designs for plastic injection moulded.
Rapid prototyping empowers teams to bring concepts to life with high accuracy and speed, facilitating real-world testing at a lower time and financial cost.
5. Functional Prototyping
Functional prototypes are fully operational models that replicate the performance and functionality of the final product.
These prototypes are critical for:
Conducting usability and performance tests.
Demonstrating features to stakeholders or investors.
Identifying and resolving technical challenges.
While functional prototypes require more time and resources to create, they provide invaluable insights into a product’s real-world performance.
6. Visual Prototyping
Visual prototypes focus on the appearance of a product rather than its functionality.
These prototypes are often used for:
Marketing purposes, such as showcasing designs to customers.
Evaluating the aesthetics of a product.
Gaining stakeholder approval for design direction.
Visual prototypes are typically made from materials that mimic the final product’s look and feel, offering a realistic representation of the design.
7. Low-Fidelity vs. High-Fidelity Prototyping
Prototypes can vary in fidelity, depending on the level of detail and functionality required:
Low-Fidelity Prototypes: Simple representations of a product, such as sketches, wireframes, or basic models. These are ideal for early-stage ideation and concept validation.
High-Fidelity Prototypes: Detailed and functional models that closely resemble the final product. These are used for advanced testing, user feedback, and stakeholder presentations.
The choice between low and high fidelity depends on the project stage, objectives, and available resources.
8. Iterative Prototyping
Iterative prototyping involves creating multiple versions of a prototype, incorporating feedback and improvements at each stage.
This approach is essential for:
Refining designs based on user and stakeholder input.
Testing and validating new features or functionalities.
Ensuring that the final product meets all requirements and expectations.
By embracing an iterative mindset, teams can systematically improve their designs and reduce the risk of costly errors.
9. Service Prototyping
Service prototyping extends beyond physical products to include processes, experiences, and systems.
This form of prototyping is often used in:
Designing customer experiences or service interactions.
Testing and refining workflows or business models.
Exploring new service concepts in real-world settings.
Service prototyping relies on tools like journey mapping, role-playing, and simulation to visualize and test service designs.
10. Virtual Reality (VR) and Augmented Reality (AR) Prototyping
Emerging technologies like VR and AR offer immersive prototyping experiences, allowing users to interact with virtual models in real-time.
These technologies are valuable for:
Simulating environments and user interactions.
Visualizing large-scale designs, such as buildings or machinery.
Conducting user testing in a controlled virtual setting.
VR and AR prototyping enhance collaboration and innovation by providing a realistic and engaging way to explore designs.
Prototyping is an indispensable part of the design and development process, offering a structured way to explore, test, and refine ideas.
Iterate, prototype, test, refine, iterate.
From simple paper sketches to advanced VR simulations, the variety of prototyping methods ensures that teams can find the right approach for their specific needs and objectives.
By understanding the different forms of prototyping and their applications, designers and developers can streamline their workflows, reduce risks, and deliver high-quality products and experiences.
Whether you’re crafting a new app, designing a physical product, or re-imagining a service, effective prototyping paves the way for innovation and success.
-----
équipe design & consulting is a Product Design Consultant in Sydney
with 20 years experience in design and manufacture of Medical grade moulded parts and product, including 5 years at the coal face as Operations Manager at a world class medical grade moulding facility; we are specialist in Design for Manufacture (DFM).
Please reach out if you feel you need assistance with your part design for plastic injection moulding.
We offer Design Coaching and Guidance to Full Service Design Consulting.
#Designforplasticinjectionmoulding #DesignForManufacturing #DesignThinking #DesignforManufacture #DesignConsulting #DesignCoaching #equipedesign #DesignforAssembly #IndustrialDesign #CREODesign
References: ChatGPT, Google Images