Basic Categories Proof of Principle Model Form Study Model User Experience Model Visual Model Functional Prototype Visual Prototype (Model) will capture the intended design aesthetic and simulate the appearance, color and surface textures of the intended product but will not actually embody the function(s) of the final product. These models will be suitable for use in market research, executive reviews and approval, packaging mock-ups, and photo shoots for sales literature.

Basic Categories Proof of Principle Model Form Study Model User Experience Model Visual Model Functional Prototype Functional Prototype (Model) (also called a working prototype) will, to the greatest extent practical, attempt to simulate the final design, aesthetics, materials and functionality of the intended design. The construction of a fully working full-scale prototype and the ultimate test of concept, is the engineers' final check for design flaws and allows last-minute improvements to be made before larger production runs are ordered.

Differences between Prototype and Production Design Fidelity Processes Materials Lower fidelity. Final production designs often require extensive effort to capture high volume manufacturing detail. Such detail is generally unwarranted for prototypes as some refinement to the design is to be expected. Often prototypes are built using very limited engineering detail as compared to final production intent, which often uses statistical process controls and rigorous testing.

Differences between Prototype and Production Design Fidelity Processes Materials Processes. Often expensive and time consuming unique tooling is required to fabricate a custom design. Prototypes will often compromise by using more variable processes, repeatable or controlled methods; substandard, inefficient, or substandard technology sources; or insufficient testing for technology maturity.

Differences between Prototype and Production Design Fidelity Processes Materials Materials. Production materials may require manufacturing processes involving higher capital costs than what is practical for prototyping. Instead, engineers or prototyping specialists will attempt to substitute materials with properties that simulate the intended final material.

Prototyping Specialist Many companies will have dedicated model shops with skilled prototyping specialists to aid in the construction of complex prototypes Prototyping specialists are often ‘generalists’ and are skilled at a number of processes which tend to make them excellent problem solvers Can be a valuable resource to the design engineer

Prototyping Specialist Many companies will have dedicated model shops with skilled prototyping specialists to aid in the construction of complex prototypes Prototyping specialists are often ‘generalists’ and are skilled at a number of processes which tend to make them excellent problem solvers Can be a valuable resource to the design engineer

Virtual Prototyping

Recommendations Get into hardware early Prototype with a purpose Build the simplest prototype that will answer your questions. Get the most out of your prototypes Get into hardware early! Never built a prototype that didn’t teach me something important or surprising. Before building a prototype What are you trying to learn? Function? Aesthetics? Usability? Select the simplest prototyping means that will answer your questions. Use prototypes to force the organization to stand and deliver. Beware of: Terminology confusion One person’s prototype is another persons… Expectation disconnects Creeping expectations Ignoring problems found during prototyping and assuming they will go away at production by themselves.

Cautions Terminology confusion Expectation disconnects Creeping performance Ignoring findings Get into hardware early! Never built a prototype that didn’t teach me something important or surprising. Before building a prototype What are you trying to learn? Function? Aesthetics? Usability? Select the simplest prototyping means that will answer your questions. Use prototypes to force the organization to stand and deliver. Beware of: Terminology confusion One person’s prototype is another persons… Expectation disconnects Creeping expectations Ignoring problems found during prototyping and assuming they will go away at production by themselves.