Product prototyping and design are processes that involve the creation of initial versions of products for testing, validation, and further refinement before launch. Modern technologies, including CAD (computer-aided design) software and simulation and modelling tools, make it possible to create prototypes quickly and efficiently. The stages are crucial in the product development cycle as they enable the identification of potential problems, optimisation of functions, and alignment of the design with user expectations.
Product Prototyping and Design
Type of technology
Description of the technology
Basic elements
- CAD tools: Computer-aided design software that enables the creation of detailed 2D and 3D models of products.
- Physical and digital prototypes: Creating product models in physical form (e.g. using 3D printing) and computer simulations.
- Engineering simulations: Tools to analyse and test the function and durability of a product under various conditions before it is manufactured.
- Functional analysis: Testing product functions and interactions under conditions of use.
- Integration with production tools: Prototyping is often combined with manufacturing support software, enabling a seamless transition from design to manufacturing.
Industry usage
- Industry: Creating prototypes of machine parts, tools, and technical components that can be tested for durability and functionality.
- Medicine: Prototyping medical devices, such as implants, prostheses, and diagnostic equipment, so that their performance can be tested and improved before launch.
- Electronics: Designing prototypes of printed circuits and other electronic components, which enables rapid testing and optimisation of performance.
- Automotive industry: Creating prototypes of automotive parts that are tested for aerodynamics, durability, and function before mass production.
- Art and fashion: Virtual prototyping and physical prototyping of artwork, clothing, and accessories, which makes it possible to design and test unique creations.
Importance for the economy
Product prototyping and design play a key role in the life cycle of products, having an impact on time-to-market and production costs. Through rapid prototyping, companies can test and improve their products before they are mass-produced, reducing the risk of errors and faulty designs. In the industry, medicine, electronics, and automotive, prototyping enables the creation of more advanced, precise, and functional solutions. The use of advanced design software also helps shorten the product development cycle and reduce testing costs.
Related technologies
Artificial Intelligence
AI supports the automation of the design process, e.g. by generating optimal design solutions and analysing simulation results.
Cloud Computing
Design and prototyping software is increasingly cloud-based, allowing remote access to designs and real-time collaboration.
Big Data
Big Data: Analysing the data from prototype tests enables the optimisation of the design and the improvement of its functionality before launch.
Internet of Things
Internet of Things (IoT): Integration with IoT systems makes it possible to prototype devices with embedded sensors to test their functions in a real-world environment.
3D printing
3D Printing: The technology is often used to quickly create physical prototypes of products in various industries.
Mechanism of action
- The prototyping process begins with the creation of a conceptual model, which is then developed in a CAD environment, where detailed visualisations and 3D models can be created. At this stage, engineering simulations are also carried out to assess the strength and functionality of the design. Then, 3D printing or other techniques can be used to make the prototype, which enables the product to be physically tested. In the next stage, functional tests are carried out and possible improvements to the design are made before mass production begins.
Advantages
- Reducing time-to-market: Rapid prototyping enables faster time-to-market through testing and optimisation before mass production.
- Cost reduction: Testing prototypes enables the identification of problems and defects during the design phase, which reduces the costs of later revisions.
- Better adaptation to users’ needs: Through prototyping, companies can better align their products with market demands and consumer expectations.
- Optimisation of production processes: Early testing of prototypes enables better preparation for production, which reduces the risk of failures and downtime on the production line.
- Personalisation: Modern design tools make it possible to personalise products according to individual customer needs.
Disadvantages
- Costly tools: Prototyping software and hardware can be expensive, which can be a barrier for small companies.
- Time consumption: Although prototyping reduces overall time, the design and testing process itself can be time-consuming.
- Technology dependence: The effectiveness of prototyping depends on the technology tools available, which may require regular updates and technical support.
- Scaling issues: Prototypes may work well on a small scale, but some problems may not arise until mass production.
- Material limitations: Some technologies, such as 3D printing, have limitations due to the types of materials that can be used to create prototypes.
Implementation of the technology
Required resources
- CAD software: Tools, such as AutoCAD, SolidWorks, and Fusion 360, that enable design and prototyping in a digital environment.
- 3D printers: Equipment to create physical prototypes based on digital models, which enables them to be tested.
- Design team: Engineers, product designers, 3D graphics specialists, and experts in prototype testing and validation.
- Prototyping materials: Plastics, metals, and other materials that can be used to create physical prototypes.
- IT infrastructure: Cloud servers and platforms to support remote access and collaboration on projects in real time.
Required competences
- CAD software skills: Proficiency in the use of 3D design and modelling tools, such as AutoCAD, SolidWorks, and Fusion 360, to enable effective product prototyping.
- Knowledge of 3D printing technology: Ability to design and convert digital models into physical prototypes using 3D printing to speed up the testing and validation process.
- Engineering simulations: Knowledge of strength and functional simulation tools, such as ANSYS and Abaqus, which enables testing of products before production.
- Project management: Competence in the coordination of the process of designing, testing, and implementing changes at the prototyping stage, including the ability to work in a design team.
- Data analysis: Ability to analyse the results of prototype testing and optimise the design based on the collected data.
Environmental aspects
- Energy consumption: The processes involved in designing and simulating prototypes, especially those using advanced software and 3D printing machines, can lead to increased energy consumption.
- Raw material consumption: Creating physical prototypes, especially through technologies such as 3D printing, requires raw materials, including plastics and metals, which can have an impact on the environment.
- Production waste: Incorrect prototypes or test models that do not pass validation can generate waste that must be properly processed.
- Recycling: In the case of failed prototypes, materials have to be properly managed and recycled to minimise environmental impact.
- Emissions of pollutants: The production of physical prototypes, especially in industrial processes, can contribute to emissions, e.g. in 3D printing and metalworking.
Legal conditions
- Legislation governing prototyping, such as product safety directives (example: EU machinery safety directive) requiring prototypes to be tested for compliance with standards.
- Environmental standards: Regulations for responsible waste management and recycling of materials used during prototyping (example: the WEEE Directive on electronic waste).
- Safety standards: Safety requirements for prototype designs, especially in medicine and industry (example: ISO 13485 on medical devices).
- Intellectual property: Protection of prototype designs and the technologies used to develop them, including patenting of inventions and industrial designs (example: copyright and industrial designs in EU law).
- Data security: Regulations for data protection and intellectual property for digital prototype models (example: GDPR in the context of the protection of design data in the cloud).