What is a prototype?
A prototype is a rough draft of a sample product that comes next in the product development stage. Usually, prototype products are short, small-batch runs that are used to measure efficacy and test the product. It is also useful to get a look, feel, and to touch the prototype.
Many manufacturing companies tend to not do prototypes for two reasons, time and money. The time it takes to set up the machine and run a 1-10 piece part is not as lucrative as a piece with a large run of 5,000+ pieces that could go in the machine instead.
Why are prototypes important?
Imagine a medical device company that didn’t run a prototype production on the connector piece of a new IV pump and just manufactures the piece of their sketch drawing instead of going through each and every step of the prototype process. Then this untested, prototype is put into the mechanism of the IV pump and sent out to hospitals to use. Patients then are hooked up to receive an IV but have no drip since the connector is not working as it should. This scenario is very unrealistic but it helps give an idea as to why prototypes are important to any company no matter the product.
Here is a step-by-step guide from Pacific Research Laboratories which gives an outlined list of each step in the process. But keep in mind not every prototype piece will follow each step by step. That is what makes prototypes a challenge, but a challenge we’re willing to take.
Steps to Prototype to Production
(Full Outline on Pacific Research Laboratories)
- Come up with a product idea
- Create a design drawing
- Create a 3D model
- Make a prototype
- Test the prototype
- Decide on production quantity
- Design molds based in quantity
- Decide what tooling/materials to use
- Quality control testing
- Sign manufacturing contract
- Manufacture products
- Assemble & ship
- Store design on CAD software
Once your prototype makes it to step 6, your chosen contract manufacturer comes into play. Communicating with a manufacturer you trust is essential, since a prototype is all about trial and error and a lot of back-and-forth communication. You might even find yourself asking your manufacturer for their opinions about the type of tooling, tolerances, and materials to be used.
After your prototype is manufactured by your chosen contract manufacturer and is cleared to be a working prototype product, a lot of contract manufacturers hope to be able to do the long production runs for that piece, since they worked closely with you in the design process.
Here at Stone Medical and Swiss Technologies of New England customers who come to us asking to quote a prototype run, we keep the same cost on prototype runs if you order larger quantities of the finished piece. With over 22 years of experience, we look forward to working with you on your next medical device project.
As Kristi, our Business Operations Manager says, there is no challenge we aren’t willing to take, that’s what helps separate us from other contract manufacturers. We will go above and beyond to help you every step of the way.
Resources:
https://www.engineersedge.com/testing_analysis/production-prototype.htm
https://www.pacific-research.com/wp-content/uploads/2020/03/prototype-to-production-683×1024.jpg
