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.