The Salient Blog

Last time, we took a look at Stage 2 of the Mechanical Development Process – the Prototyping Stage.  We’ve also explored Stage 1 – the Conceptual Stage in a previous post.  Here, we’ll be delving into the third and final part of the Mechanical Development Process – the Production Stage!

Production Stage: The final stage of mechanical development is the Production Stage where, once a concept has been validated through market research and prototype testing, the final design changes take place. Production design is often finalized by the product company, manufacturing facility or by a third party consulting firm. Sometimes this calls for a final “production-ready” prototype as many companies and manufactures find prototypes of this nature necessary for to validating the design prior to investing in expensive tooling and inventory. Final tweaks occur at this stage to ensure manufacturability and to reflect cost considerations. This final design, excluding versions 2.0, 3.0 etc, include manufacturing methods, 2D engineering drawings, 3D CAD files, materials selections and fully defines all components.

Most successful products follow this three stage process.  A bit of variation exists as some simple projects seem to fly through straight to the store shelf while others require a bit of iteration and testing.  However, they all typically touch on Concept, Prototype and Production, in that order. It’s important to keep the entire process in mind while developing. For example, ask at the early stage, “Can this be made?”; and when it is ready for tooling ask, “Is this the product we intended from the beginning?” While being cognizant of the whole path, one does not want to skip ahead or miss necessary steps.  Since each stage requires greater investment than the previous one, it behooves inventors and companies to move in the proper order of development so they don’t spend unnecessarily. Following these stages also helps define how far along a project really is and better determines the current value of an idea. The closer an idea is to becoming a product, the more it is worth!

David Yakos is the VP, Director of Creativity at Salient Technologies, Inc.

In our last post, we explored Stage 1 of the Mechanical Development Process – the Conceptual Stage.  In this post, we’ll explore Part 2 of 3, the Prototype Stage!

Prototype Stage: Once a plausible direction is determined by the conceptual stage, the prototype process can begin. The prototype stage is often repetitious as products evolve and develop.  Prototypes are essential to validating a concept since they allow designers to test, feel, hold, use and experience the product in a way that a simple sketch or rendering cannot.   It is wise to keep in mind the end goal of manufacturing when designing for a prototype to help narrow down materials and manufacturing processes.  Often, prototypes are created as a “proof-of-concept” to validate form and functionality, and are also built as show-pieces to generate interest in a product.  The prototype stage allows designers and inventors to catch flaws and visualize enhancements at a relatively early and inexpensive stage.  Inventors stand a much better chance at generating interest in an idea if a concept is proven through the prototype stage rather than just a conceptual sketch. 

 The intricacy and cost of prototypes may vary greatly, but even an inexpensive prototype made from clay and cardboard can validate a concept. However, in order to validate a design a more sophisticated approach may be needed. More intricate prototypes can come from designs modeled in 3D CAD as a virtual prototype, then rapid prototyped (3D printed) and finished to represent a final product.  Higher quality prototypes are essential for trade shows, marketing and confirmation of a concept prior to moving into the production stage. Taking a solid idea this far is a strong position for the independent inventor looking to license the product. Prior to production, companies will often make changes to a design, so unless the inventor is the one manufacturing and distributing the product, it makes sense to hold off on investing beyond the prototype stage.

Check out the final part of this series, the Production Stage!

David Yakos is the VP, Director Creativity at Salient Technologies, Inc.

New products appear in company catalogs and on store shelves every season.  We don’t often give thought to how they transformed from an individual idea to a tangible product. Remarkably, this mysterious process can be summed up in a few simple steps. Whether it is a new puzzle game or a complex valve for the space shuttle, there is a well-defined three-step route that nearly every product follows starting with a Conceptual Stage, followed by Prototype Stage, and finally the Production Stage.  In this post, we’ll look at Step 1…

Conceptual Stage: Products start out as ideas which are often sparked by a challenge, competing product, gap in the market, inspiration from alternate industries, or the more unconventional “I woke up in the middle of the night with this great idea.”  The first thing to do with this idea is write it down, move it from in-between your ears onto a piece of paper which, unlike humans, will never forget it.  The conceptual stage has begun. Once on paper, an idea has hatched and can begin to grow. This is where brainstorming leads to the validation and the definition of the idea. Now’s a great time to be honest and ask some early questions: Does this already exist?  Is there a market? Can it be made? What would it cost? What would I make it out of? Who would use it? What would it look like? Would people want it? And better yet, would they pay for it? Are there other ways of doing it? Should I protect it? Is it timely? Is it worth it? 

 The course of the product is often defined at this first and often least expensive stage. An industrial design sketch or conceptual CAD model at this stage may capture the look, materials and form which are carried all the way through prototype and production design. Many inventors only take an idea through the conceptual stage finishing with some quality sketches, renderings or perhaps an animation.  At this point, the product concept is defined enough for market research, presenting to management, or attempting a licensing deal. However, in order to validate an idea or better sell the vision, one must often move into the Prototype Stage which we’ll explore in Part 2!

David Yakos is the VP, Director Creativity at Salient Technologies, Inc.