that become tooling disasters
Prototype failures are recoverable at low cost. The same failures discovered at tooling are recovered at high cost and long delay.
Prototype process does not match the production process
A CNC-machined aluminum prototype of a product that will be injection-molded in ABS may validate the form and dimensions but cannot validate the structural integrity, surface finish, or tolerance stack-up of the production process. The prototype must test the variables that the production process introduces.
User testing skipped to accelerate the schedule
A product that functions correctly in an engineering test but fails in user testing has a problem that cannot be solved by tooling. User handling reveals grip issues, interface problems, and misalignments between the product's assumed use model and the user's actual behavior. Discovering these after tooling is an expensive redesign.
Single prototype, no iteration
One prototype that looks close enough is approved for tooling. The next time the design is reviewed is at first-article inspection. The issues that would have been found in a second iteration are now tooling problems. The cost of the missing iteration is the tooling correction plus the delay.
for three validation objectives.
Each prototype type tests a different aspect of the design. The sequence is defined by what must be validated before the next decision is made.
Concept Prototype (3D Print / SLA)
Rapid concept prototypes for early-stage form and aesthetic validation. Fast to produce, low cost, not suitable for functional testing of structural requirements. Used for early stakeholder review, size and proportion validation, and ergonomic assessment.
Functional Prototype (CNC / Urethane Cast)
Functional prototypes for structural, mechanical, and operational validation. Material and process selected to approximate the production process. Used for engineering validation, regulatory testing samples, and supplier quotation.
Pre-Production Prototype (Production Process)
Prototypes produced using the actual production process and tooling: injection-molded first-article parts, PCBA assembled on production-intent fixtures. Validates that the design performs as expected when produced by the factory under production conditions.
Each iteration tests a defined hypothesis.
Prototyping without a test plan is expensive trial and error. Every iteration tests specific hypotheses and has defined pass/fail criteria.
Prototype Test Plan
Before each prototype iteration, a test plan is defined: what hypotheses are being tested, what the pass criteria are, and what decisions the results will inform. The test plan prevents iteration without learning.
Prototype Production & Testing
Prototype produced by the appropriate method for the validation objective. Testing conducted against the test plan. Results documented with photographs, measurements, and functional test data.
Iteration or Tooling Approval
Test results reviewed against pass criteria. If criteria are met, tooling is approved. If not, the design is revised and the next prototype is produced. The iteration count is determined by the test results, not by the project schedule.
for tooling approval.
Tooling is approved only when the prototype has passed all defined tests. Not when the schedule says it should.
Defined hypotheses, test methods, and pass criteria for each iteration.
3D-printed or SLA models for form and aesthetic validation.
Structural and operational prototypes with test data.
First-article production prototypes with inspection documentation.
Documented results for each prototype iteration with decisions made.
Pre-production samples produced at CNBSolutions factory partners where applicable.
Product Development includes additional services that compound on this one.
Iterate at prototype cost,
not at tooling cost
We work through referrals. If you have been referred, send us a message and we will review your current design and identify what needs validation before tooling.