Course to Fine Prototype Development Process

David Bolognino

Expert-in-Residence, Centrepolis Accelerator

The process of helping LTU-CA clients create physical products is an exciting and rewarding part of my role as Expert in Residence.  In that role, just like in my 35-year career in the auto industry, I often see inventors and designers succumb to the temptation to have the physical prototype serve as the exclusive outcome of their work. They incorrectly think that a beautiful shiny object, perfect in every detail and meticulously executed will elate their leadership or potential investors.  More often than not these objects, that are created very early in the process, only become the basis for iteration.  As such, these expensive and time-consuming prototypes become nothing more than “dumpster art”!

When working with clients I try to get them to think in terms of a course to fine prototype development process. The physical prototype is only one tool in the product development process. It should be created with a clear purpose and be of the least fidelity required achieve that purpose; efficacy testing, market clinics, etc.  It is intended to compliment but not supplant other tools in like business plans, pitch decks or renderings.  

Early prototypes should be constructed such in a way that will allow quick iteration. It can be best described as a “fat pencil” activity. Materials like clay, cardboard, foam and duct tape can be used by those with even the most basic skills.  Components can be cannibalized from items with similar attributes to speed the creation process and save cost. This process will help rough out the basic fit, form and some functionality.  Continuing to refine a design prototype may include the addition of plastics, 3D printed components and electronics.  Electronics can be executed using products designed for the experimenters like plug in circuit boards and Raspberry Pi controllers.  

It is only after the iteration phase has concluded, full computer aided designs (CAD) have been created and any relevant analysis (FEA, FMEA, DFMA)* has been performed is it time to make a highly detailed and finished physical prototype. These prototypes are usually produced by professional model makers with prototype methods such as 3D Printing and CNC machining. While these prototype models can be quite costly, adhering the appropriate course to fine product development methodology will insure they are a wise investment.

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*FEA – Finite Element Analysis; FMEA – Failure Mode and Effects Analysis; DFMA – Design for Manufacturing and Assembly

“If you aren’t embarrassed by the first version of your product, you launched late.”

-Reid Hoffman founder of LinkedIn

“Fail early, fail often, in order to succeed sooner.”

-Tom Kelly; author and partner at the innovation consultancy IDEO