05Prototype & Test
Prototypes and pilot builds, tested against the specification
A first build that answers what analysis can’t: how it feels, how it goes together, how it behaves in use. Made by the process that suits the question.
Every prototype should have a job. A presentation model shows how the product looks. A functional prototype proves fit and mechanism. A low-volume pre-production build shows whether the production route works before tooling money is committed.
Prototypes can be additive, machined or a mix of the two, in polymers, composites, aluminium or stainless steel, with finishing where appearance matters. Where analysis has already answered the question, we say so. Sometimes the best prototype is the one you don’t need to build.
What you leave with
- Prototypes with a purpose
- Parts built by the process that suits what they need to show.
- Results against the specification
- What met the specification, what didn’t, and the design changes that follow.
- Images before the product exists
- Photorealistic renders for marketing and launch, made from the same CAD.
Questions this stage answers
Do we always need a prototype?
No. Where analysis gives a clear answer, a prototype can add cost without telling you anything new. Where feel, assembly or real use matter, it earns its place.
Which process should we use?
It depends on what the part has to prove. Printing is quick for form and fit; machining gives production-like strength; a mix suits assemblies.
Can you make a short run for trials or investors?
Yes. Low-volume pre-production builds use the same CAD and process data as production, so they behave like the real thing.
Can prototypes look like finished products?
Yes. Surface finishing, coatings and assembly detailing bring presentation models close to production quality.
Case study
Over 15% lighter than the original designs, with no loss of durability.
A lighter line of high-end fishing reels
A client in the fishing equipment sector wanted a new reel line with patentable improvements that would also be easy to manufacture.
Guides for this stage
Discuss your project
