Making Your Prototype

  • Posted by: Robert DeBardeleben
  • Category: Prototypes
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High volume production line.

Making Your Prototype

Perhaps the most common request we get from our inventor clients is regarding prototypes. Unfortunately there is a lot of misconception out there that defines just what constitutes a prototype. We have been contacted by a  number of inventors that have first worked with those TV invention help companies, looking to have their designs made into a prototype. After paying a substantial amount of money for their idea to be “designed”, the client approaches us believing that their design is ready for prototyping. Upon inspection of the work completed in every case we have to tell the client that what they have is nothing more than a cartoon.

These cartoons often are more like what we call around here “Acme Products” reminiscent of the products delivered to Wiley Coyote in his attempts to capture the Roadrunner. What I mean by that is a cartoon of something that is physically impossible to actually turn into a real tangible product. Cartoons depicting a product that folds up or out impossibly small for what it takes to make the device. For example, we have seen cartoons depicting telescoping legs that start out when stowed as something that might be only an inch tall, when stretched out ends up many feet long, with dozens of segments!

Because of these invention companies we had to implement a couple of policies here at Ignite. The first one being that we refuse to take on a project that would require the violation of the laws of Physics. The second policy is that we will not take some other firm’s “engineering package” and convert that to a prototype without our engineer first reviewing every aspect of the engineering package. Of course, having one of our engineers go through an entire design submitted from a different firm will result in a massive waste of money for the client. Recommendation….have Ignite design it from the onset and make your prototype too.

Evaluating a cell phone prototype.

We define prototypes in several ways. To characterize what a prototype is, we have created six “Levels” of a prototype starting from Level 5 as a crude, almost home-built prototype to Level 0 which is a first article example of what came off the production line. When we make you a prototype it will meet one of these levels, with each level being an essential element of the product development process.

Here at Ignite Product Design we have the ability to manufacture prototypes as well as production items through our fully vetted network of manufacturers, both foreign and domestic. Any number of prototypes may be required during the process of maturing a product. Prototypes may not perform as intended, however they are the basis of gaining knowledge. It is highly recommended that the intended product go through a full prototype development process.

Level 5 Prototype: A crude assembly of easily obtainable parts and materials. This can be an effective way of better understanding a theoretical principal or process. Used to establish basic parameters which can be expounded on by Engineering discussions.

Level 4 Prototype: A lower quality prototype using non-production manufacturing methods such as CNC machining or 3D printing. This prototype is structurally non functional but may look similarly to a production version. Often used to present the product concept to investors or crowdfunding.

Level 3 Prototype: A lower quality prototype that focuses on proving function. This prototype is used to perfect moving mechanisms, electronic functions, etc. This prototype may have no visual relationship to the final product. Used for bench-top functional testing only. Sometimes a Level 3 Prototype is demonstrated along with a Level 4 Prototype when presenting to potential investors.

Level 2 Prototype: A more advanced prototype using non-production manufacturing methods. This prototype combines what was learned from Level 4 and Level 3 prototypes into a single prototype having both higher quality looks and functionality. Used for more detailed testing and evaluation. Several Level 2 prototypes may be required before a Level 1 Prototype should be considered.

Prototype PCB cooling fan assembly.

Level 1 Prototype: A production quality part or assembly using non-production manufacturing methods. Used to perform more detailed verification of engineering design and details before production tooling is manufactured.

Level 0 Prototype: A first article production part using production tooling. Used to determine whether the production tooling is producing acceptable parts before first production run.

Depending on the goals of the client, we can tailor the level of prototype we deliver in order to meet the needs of the client. Since we do not require any contractual commitment, we can stop anywhere in the process that the client needs, including the point at which the client is ready to test the market to see if there is demand for their invention.

Robert DeBardeleben