The product development process usually starts with the design process and leads to the prototype development process. Creating a prototype is an essential step in developing new products or technologies. It is a physical representation of the conceptual project, used to illustrate and verify various aspects of it.
A prototype can be anything from a simple hand-made model to a fully functional representation of how the conceptual design will look and function under real-world conditions. With the development of rapid prototyping, it is quite easy for manufacturers to create a prototype and verify the design in less time. This prototype helps convince customers and expand the product's market.
Rapid prototyping techniques
From reducing costs to increasing efficiency – rapid prototyping technology has an impact on the industry. Rapid prototyping is a set of techniques that can be used to create the physical prototype or product in less time compared to other manufacturing techniques. Rapid prototyping has made the prototyping process easier, more accurate, and less time-consuming. The product is usually manufactured using a 3D printer or other additive manufacturing technology using CAD model data.
CNC machines are also used nowadays to convert the 3D model into a physical model. Model data must represent valid geometry for rapid prototyping. The difference between a 3D printer and a CNC machine is essentially the material and tools used in the prototyping process. Additionally, a 3D printer requires much less space compared to traditional tool room subtractive methods such as CNC milling, turning, and precision grinding, making it a much more affordable option for manufacturers. The availability of modeling software also plays a key role in the increasing use of these rapid prototyping techniques. This new software has a user-friendly interface that makes it easier for private and industrial users to model a 3D model of the product.
In rapid prototyping, the following technologies are often used to develop prototypes:
- 3D printing (3DP)
- Shape Deposition Manufacturing (SDM) (and Mold-SDM)
- Solid Soil Hardening (SGC)
- Selective laser sintering (SLS)
- Selective laser melting (SLM)
- Stereolithography (SLA)
- CNC processing
- Ballistic Particle Production (BPM)
- Directed Light Manufacturing (DLF)
- Direct Shell Production Casting (DSPC)
- Fused Deposition Modeling (FDM) – process for producing plastic resistant to high temperatures
- Laminated Object Manufacturing (LOM)
- Laminated Resin Printing (LRP)
Prototype Categories
A prototype can be categorized according to the conceptual design and the final product to be developed
1. Functional prototype
A working prototype is developed that represents almost all of the features and functions of the final product.
2. Visual prototype
A visual prototype represents the shape, dimensions, and appearance of the conceptual design, but is not intended to represent the functionality of the final product. This prototype development process is simpler than the previous process.
3. User Experience Prototype
It is designed to represent enough detail of the final prototype to be used in future research.
4. Functional prototype
A working prototype and a functional prototype are similar prototype development processes, except that the working prototype may be created using a different technique and on a different scale than the actual product.
Importance of the prototype development process
The prototype development process is an important part of product development. A prototype developed from the conceptual design helps determine many factors of the final product, which are described below.
1. Project evaluation and testing
By creating a prototype, the design can be evaluated under real-world conditions so that different parts can be evaluated. This allows the manufacturer to determine which parts of the design need to be discarded or revised, which was not possible on paper. The manufacturer can also test and evaluate the product under real conditions before entering the production phase.
2. Determination of costs and production problems
Developing a prototype before actual production allows the manufacturer to get an overview and determine whether or not the production process needs to be changed. This allows production costs to be reduced to a minimum. Furthermore, any difficulties in the production process can be identified, allowing the manufacturer to choose the optimal production method that costs the least and is error-free.
3. Sell the product
A prototype will attract more customers than a conceptual design. It's much easier to sell a product with a prototype than with a conceptual design because it's harder to explain the design to each customer. If the customer is taken into consideration during the prototype development process, the manufacturer can edit any part of the design according to the customer's wishes, which is no longer possible after product development.
Difference between prototype and real product
Although engineers and developers do their best to minimize the differences between the prototype and the real product, in general, a prototype may differ from the real product in terms of material used, machining process, appearance, etc.
The material used in the final product is expensive and difficult to manufacture. Therefore, a prototype is usually made from a material that is easy to manufacture but whose properties are identical to those of the final product. In some cases, the material used in the final product is not available, so the prototype is made from the same material. The difference in material can change the appearance and finish of the final product in relation to the prototype.
Final products often need to be manufactured in large quantities, so the manufacturing process can vary. The final product is usually manufactured using a mass production method that is cost-effective and time-saving. This manufacturing process often cannot be used for prototype because the material is often not the same. Furthermore, the manufacturing processes of the final product can be complex, so the prototype is often made using a simple technique. This can also result in a difference in the appearance of the final product and the prototype.
Final considerations
It is clear that the prototype development process is an essential part of the industry. The prototype reduces many errors in the conceptual design that would have caused many problems during the product development process. There may be differences between the prototype and the actual product, but in any case the real purpose of the prototype is fulfilled and supports product development in several ways as described above.
