What is “Prototype X”?

Your speed to “Prototype X” determines your success. In this article, I’ll tell you why and also how I’ve shaved weeks off my path to Prototype X.

“Prototype X” is the next major prototype you need to move the project ahead. It could be the concept prototype, production prototype or the DoTTEW (DOes This Thing Even Work) Prototype. Here are tricks I have discovered to speed up my prototyping. And even though I can often make a prototype in a day, I still want to make them quicker.

To speed prototyping,

1. I’ve standardized on suites of core tools
   a. ATMEL MCUs
   b. Eagle CAD (PCB & Electronic Design)
   c. Fusion360 (CAD/CAM/SIMULTAION)

2. I’ve deeply learned how to build difficult components in-house
   a. I use SLA and FDM to make gears/cases/parts out of resins, PLA, ABS and other plastics to quickly go from idea to physical object.
   b. I machine Printed Circuit Boards (PCB) in-house. So I get electronic prototypes in one day instead of two weeks.
   c. I get functional nylon and metal parts in a day using CAM and a CNC Mill or Lathe or both.

3. I’ve filled my shop with tools that let me use many different methods of production. I own and know how to effectively operate…
   a. Several different 3D printers (SLA/FDM)
   b. Large Laser Cutter
   c. CNC Mill and Lathe
   d. Plastic injection molding machines
   e. Thermoforming machines (in several sizes)

4. I’m a prototype realist. Prototype X is important, but not the journey to it. You’re making a prototype, not a story.
   a. I make the prototype to solve the problem. Meaning if I’m testing functionality I often put looks second. But if I’m presenting a prototype for evaluation by a potential customer, then I put looks at or equal to functionality. The idea is to quickly get to Prototype X and sometimes it doesn’t matter if it’s red or blue or no color.
   b. I don’t make parts I can buy. If your prototype needs a part you can buy, then just buy it. The prototype is important, not each piece.

5. Brutal honesty is better than kudos
   a. Quickly evaluate the prototype. Do it as you first use it.
   b. If it works, great, move on to the next phase of the project. If it does not work then determine why.
   c. Kill the prototype if it needs to be killed. Let this version of the prototype die with dignity and move on.
   d. Have others test it. But don’t tell them what to think, listen to them.

These are some of the things I have learned while making prototypes over the past few decades. I’d love to hear your thoughts too. I’m always looking to speed up my prototyping and am sure you have a skill or two that would help me.

What ideas do you have about prototyping?
What skills/tricks have you learned that help you?
What is the most important tool in your prototyping arsenal?

Please, share below. We can never make a prototype too fast.