Prototype Production | Next-Generation Tape Cutter | Product Development

We developed a solution to the difficulty of cutting T-Rex Tape. The process of product development and prototype production required a lot of experimenting and design modifications. More than several dozen prototypes were produced during the process of product development.

Because we are a “one-stop-shop” for product development, rapid prototyping is one of our everyday activities. Through many prototype production-testing-design modification cycles, we came up with the product that was easy-to-use and relatively simple to make.

At the end of product prototype development, we found a few alternatives to choose from. However, we chose the one that is on the market now for several reasons. First, it is one of the simplest designs, an important design factor for this project. Second, the design assembles easily. Finally, this design reflects the sharp lines and formidable look of a T-Rex dinosaur.

Working with LA NPDT Tadpole created the first tape cutter that could easily cut the strongest tapes on the market.

Through product design, development, and prototype production with LA NPDT, Tadpole got the resources necessary to take an idea from prototype to manufacturing. Completing the project in a timely manner allowed the company to be a part of an emerging market of highly-engineered tapes.

The final product is a two-piece design featuring the Safe Flex Blade Technology. A perfect item for a market that demands high-performance and cost-effective tools.

Finally, this tape cutter not only fulfilled a market need but also served as a basis for future developments in the performance tape industry.

Prototype production at a glance

Scope	Design refinement, functional prototypes, testing, production documentation
Methods	3D printing, machined parts, short-run assembly
Deliverables	Working prototypes, test findings, production CAD and drawings
Typical timeline	2-6 months

Mechanisms have to be built to be believed

A cutting mechanism can look correct in CAD and still bind, dull quickly or require two hands. Blade geometry, spring force and the way a user loads tape are all discovered by building and breaking prototypes, not by reviewing screenshots.

How the T-Rex developed

We built successive functional prototypes, each testing a specific question — cut quality, loading speed, force required, durability across cycles — and kept the changes that survived. Once the mechanism was stable we documented it for production, converting prototype-only features into moldable, assemblable parts.

Frequently asked questions

How many prototype rounds are typical?

Two to four for mechanical products; each round should answer a defined question rather than change everything.

Can prototypes be used for demos and investor meetings?

Yes — we finish presentation units to look and feel like production product.

What does prototype production cost?

Functional mechanical prototypes typically run $2,000 to $15,000 per round depending on part count.