RAPID PROTOTYPING COMPANY

Prototyping is an integral part of product development. This is where craft, sciences, and technology meet to bring your idea into a physical world. Prototype manufacturing is usually done by rapid prototyping companies.

First of all, a prototype is needed to determine the feasibility of your idea design. It also helps to identify opportunities for improvements, streamline manufacturing, and overall reduce the cost of your project. Prototype manufacturing is a creative process, which helps you to improve your invention in terms of performance, appearance, and market fit.

Due to the importance of prototyping to the overall market success of your idea, we invite you to dive into this subject with us. It’s important to have all the necessary knowledge and tools at your disposal. No matter what stage of product development you are at, you will be able to make the right decision about your prototyping needs. Let’s start.

A prototype is a tangible sample or model of your product idea. It is not a final product by any means. You might need a prototype to perform marketing surveys, fundraising campaigns, or preparation for manufacturing among other reasons. In some cases, a 3D virtual prototype might be sufficient.

Above all, a physical prototype gives you an opportunity to really feel and touch your invention. You can see its strengths and weaknesses, and modify the design so that your final product will work as intended.

A physical prototype at your disposal is a very useful tool. You can see the real size of your product, how the selected materials are behaving, what they feel like, and what their true colors are. Having all that physically available enables you to make observations and ask for feedback from your product’s end-users. Then you can play with design iterations as necessary for the betterment and optimization of every detail of your product.

How many prototypes are needed?

It’s almost never the case to have just one prototype during a product development process. Usually, you need several prototypes in order to achieve a perfect balance between functionality, performance, production costs, and visual appearance of the product.

Of course, nowadays, due to technological development and the existence of rapid prototyping companies, the process of product development became faster. All that allows you to reduce the number of iterations dramatically.

There is an important aspect of building physical prototypes when it comes to manufacturing. Oftentimes, inventors take risks of investing in product manufacturing without having a prototype made. That choice usually leads to a quite substantial loss of money. Yes, they save some by skipping a prototyping stage, but they lose more in the long run.

Overall development process and prototype manufacturing help find the design flaws. It also shows how much time and resources the assembly process takes. To correct those issues the molds would have to be corrected or even changed completely. However, to fix those problems during the prototyping stage will not require substantial investments. So then, those who skipped the prototyping have to pay more for the design and tooling modifications. But they could’ve avoided that by having an invention prototype made first.

There is also a less quantifiable aspect – how much consumers will like your product. Typically, the prototype testing reveals possible design improvements. Some of them could lead to higher product appreciation and consumer satisfaction. For example, improved ergonomics could result in customers using your product more often because it feels more comfortable to them.

The more time you spend testing the prototypes and optimizing your design, the more perfected your product will become. Of course, it’s important to know when the product is good enough for your target market and when to stop. At that point all additional changes and improvements will yield diminishing returns.

1. An entrepreneur raising capital for his/her idea
2. An inventor who wants to license his/her idea to a larger company and needs it for presentations
3. A small business looking for distribution channels and ways to secure deals or pre-orders prior to larger investments to manufacturing and marketing
4. A small business that wants to test the market with its new product
5. A dreamer who had this idea for years and wants to develop a product for him-/herself and potentially sell it to others

Prior to ordering your prototype, the number one step is to understand why you need a prototype, what you want from it, and where you are in the product development process.

After those questions are answered, you can set your goals accordingly. Share these goals with your product development team, so they can help you choose the best option to move forward with.

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Back in the day, invention prototypes were made by handcrafting or machining. Such approach took longer to prepare the product for manufacturing, thus increasing time to market. With the development of computer technologies, 3D printing, and other rapid prototyping techniques, the process of prototyping became faster and more efficient. At present, rapid prorotyping companies can create virtually everything that would be impossible even a couple of decades ago.

Rapid prototyping companies use a variety of techniques to create a scale model of a product or a component. Often a three-dimensional design is created using a CAD (computer-aided design) program. The detailed item can then be produced using different methods, including 3D printing, water jet or laser cutting, and CNC machining very quickly.

The main goal of prototyping is to detect flaws, correct them, and find ways to further improve your invention. The faster you do it, the more resources you can save in the long run. Rapid prototyping gives everything necessary for that to happen.

There are many different prototyping techniques and equipment used by rapid prototyping companies nowadays. At LA NPDT we use a variety of them, including:

• Metal casting
• Silicone rubber molding
• Low-volume injection molding
• Water jet, plasma, and laser cutting
• CNC machining (turning, milling, routing)
• 3D printing (FDM, SLS, SLA, PolyJet, DLP, FDM+Continuous Fiber)
• Sewing
• Thermoforming
• PCB prototyping
• Manual machining
• Software prototyping
• Breadboard prototyping

Watch this video, where our Project Manager and Engineer, Matthew Williams, talks about different 3D-printing technologies and some of the materials we use for prototype manufacturing.

Prototyping is a combination of science and art. It requires engineers and designers to have keen technical skills, along with the ability to think outside of the box and utilize a creative approach to problem-solving. Prototype 3D printing, for example, is not that easy as some people imagine. It has specific steps to it, like converting CAD files to a format a particular 3D printer can work with, then adding support structures, and slicing the models layer by layer.

In order to successfully 3D print a part, you need to think through how each element would be printed so you could arrange the parts accordingly. It’s also important to consider how the parts will be assembled and used, and what tools and techniques you need for putting them together.

During this process you might identify features that would need to be changed. Because prototypes help to discover new ways for improvement you can optimize your prototype design. If you need a prototype for a presentation, and it must look impressive, a professional artist can apply their crafting abilities to make it appear as a finished product.

The steps needed to make a product prototype can be boiled down to the following:

• Preparation
• Making parts
• Pre- and post-assembly parts processing
  (filing, polishing, flattening, fine-tuning, etc.)
  
• Assembly

Each of those steps is a craft in itself, a mix of tech and human resources to bring out the best product possible.

Rapid prototyping companies or product development teams start tackling the prototyping process after they know the purpose of the prototype. It typically goes from a rough model to a more polished and refined one. However, the process might be different based on your product prototype’s goal.

It may require dozens of models or just a couple of them, depending on how complex your idea is. Generally, the more prototypes you build the better your product becomes. However, it’s important to remember that the expenses grow with each prototype version.

The following steps describe the overall process of invention prototyping regardless of the product prototype’s goal.

Designing and 3D modeling of your product idea based on what you want to accomplish with your prototype.

Building an initial prototype to prove the concept, to make sure that the core idea of your product is functional. It enables you to:

1. See the physical dimensions of the product
2. Determine their correctness and make iterations, if needed
3. See ergonomic aspects
4. See how the product will look

After evaluating and testing the first prototype some design modifications might be needed. When all necessary changes and iterations are implemented, the next prorotype is approved for building. This process applies to every consecutive model followed after the first rough product prototype

Many design mods are usually done and several models built by this step. Any type of prototype can be considered final, depending on its purpose: functional prototypes, mockup, demo or pre-production prototypes

Upon completion of the prototyping stage, it’s time to move to the next one. It could be running marketing surveys, conducting presentations, or getting ready for your product manufacturing.

If your next step is manufacturing, you will likely need to produce molds (tooling) and jigs that would allow cost-efficient production and assembly of your product. Once the tooling is produced, the first articles (samples) are made. Based on their quality and finish, some modifications might needed for the molds.

For example, sandblasting plastic injection molds will provide a rougher finish while polishing the cavities surfaces will result in a smoother finish. Molds can also be slightly modified to increase or reduce the size of the parts, or to add/remove some design features.

When all possible changes are implemented, then you have your final manufacturing sample. Now, you are ready for the first batch production. The main difference between a manufacturing sample and a product prototype is that prototypes are built with the use of rapid prototyping technologies and materials. That typically results in rougher finish and lower performance characteristics.

Manufacturing samples, on the other hand, are made with tools, materials, and machinery designed specifically for the production. Thus, your samples will be the exact representation of the product which will hit the market. At the same time, prototyping is a step necessary prior to mass manufacturing. So, some rough finish or a wrong color doesn’t matter much until it turns into a manufacturing sample.

Many entrepreneurs have a question regarding where on the timeline of the product development process they should start making a prototype. Our years of experience, as a product development team and a rapid prototyping company, made it clear that building a prototype should start after completing prior art search and concept design, and before filing a patent application. It is crucial to test functionality and optimize your invention’s design before investing in patents.

There is no universal cost for building a prototype because every project is unique. Each new product is a new project because it has never been created before. That is why it requires a custom approach to everything, including its price estimate.

The cost of building a product prototype depends on the following factors:

If you want to find out the cost of building a
prototype of your idea click the button and get a free estimate.

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If we put the cost estimate under a general umbrella, then it can be said that between 15% and 50% of your product development budget will be used for the prototyping stage. The fact that each project is different and requires a custom approach makes invention prototyping quite expensive. Producing one or two items of anything is expensive. Producing a couple of uniquely-designed items that have never been made before is even more expensive.

We can’t apply the economy of scale here. It is because the costs of raw materials are exponentially greater when you buy them in small volumes for building prototypes. Sometimes, a particular design requires the use of expensive machinery, which increases the overall cost of prototype manufacturing.

Moreover, building prototypes requires a highly professional team of experts with various backgrounds, such as engineering, manufacturing, designing, marketing. In addition to the technical skills, the team needs to be able to work in collaboration and know how to navigate through the magnitude of technologies available now. It also needs to be capable of generating new ideas that would bring the best version of your product to the market. Human resources are always appreciated, but skilled and experienced professionals, and their time, are valued even more.

Learn more about how much it costs to make a prototype here – https://lanpdt.com/how-much-does-a-prototype-cost-to-make/

Watch this YouTube video to learn more about reducing the cost of your prototype: https://youtu.be/Zn5mw8uOkG8

Generally, building a prototype can take anywhere from 1 day to 12 months. Sometimes it takes longer, depending on the complexity of your product design. For instance, 3D printing might take from several hours to few days.

Of course, there are unique cases when you need even more time. As an example, we had a project at LA NPDT when each part of the product took 4-5 days to get printed, which resulted in 2 months of 3D printing only. But usually, we spend between 1 to 2 months to build an invention prototype.

Back in March 2020, we took the initiative in helping and donating face shields to health care workers and first responders due to the emerged pandemic. We made the first working prototype for the product in a day and were able to further refine it in a couple of weeks. During that time we worked on a variety of aspects, including print and assembly time, design ergonomics, and jigs that helped to speed up the production process.

Since we’re talking about time, let’s explore how you can efficiently use your time while your prototype is being made. From the day you begin your product development, every minute is of great importance. So, use it wisely. Start designing your marketing and commercialization strategy, build an audience around your product.

If you already know your market, then use social media to communicate with your potential users via Facebook, Instagram, or any other platform. Take time to develop a website and newsletter campaign, so there are various ways for you to stay in touch with your audience.

Writing blogs will enable you to attract early adopters of your product. For example, you can write about the product you’re developing, issues you’re addressing, and what solutions your product idea will provide. Or you might want to share just helpful information about the issues your product helps to solve or your product’s audience is interested in.

Even before your product enters the market, you will already have a loyal audience. They will follow your progress and will see you not only as a salesman but as a person who cares about their wants and needs. They will know that while you were discussing common interests and sharing your knowledge with them, you simultaneously have been working on bringing the real solution to their problems.

Covering your invention prototyping or product development process will greatly enhance trust between you and potential users and/or partners, their interest and support. Post photos and images of the process on your social media channels.

If you’re working with a product development team or rapid prototyping companies, ask them to send you pictures, short videos of how the process is going, or some of its highlights. All these steps together will make the launch stage much easier for you. But don’t forget to consult with your IP advisor (attorney) prior to posting detailed information and visuals of your product.

There are many other ways for you to create a buzz around your product. Apply your own creativity and give it a special zest. In this case study on prototyping, you’ll find more specifics and tips regarding how to efficiently use your time. We derived those suggestions from our personal experience working on many different products, including the UP Shield.

https://lanpdt.com/product-development-within-a-couple-of-weeks/

Collaboration is a key to the invention prototype development process. When going for rapid prototyping companies, look for the one that will be a part of your team. At LA NPDT our designers and project managers not only work with our engineering and prototyping teams but also with you. Becoming one unit is crucial when it comes to designing your products.

The obvious question arises among product developers about the benefits of working with rapid prototyping companies versus manufacturers. We’ve got four main aspects that will help you make a decision on how to go about developing your prototype and what features to look for when choosing a prototyping company

Not all manufacturing companies build prototypes. It is because the profit margin is lower compared to bulk orders, while the amount of work is larger and the risks are much higher. Plus, they might not have the necessary time and resources to put into your invention prototype.

Whereas rapid prototyping companies have everything required for building a prototype because that’s what they’re there for. It might also be a smart idea to choose a company that will not only provide you with prototyping services but will help you at all stages of product development. In other words, they’ll be carrying your project from idea to manufacturing and bringinging your product to the market.

At LA NPDT we invest a great amount of time and attention to truly understand your goals and vision. We become one team with you from the very beginning of your project. Therefore, we’re making sure that your expectations about what your product should be align with what we develop and build.

Manufacturers in most cases want to produce in large quantities. If they take on a prototyping project they want it to become a large production order quickly. Some would even ask to sign a Letter of Intent (LOI) that would mean you’d be using them for manufacturing.

Typically it’s too early to decide on a manufacturer during the prototyping stage. You still need to work out the design and finish the development of the product. An early manufacturing commitment will narrow your opportunities to reduce production costs, at the very least.

In most cases, there might be other manufacturing companies that can give you a better deal when it comes to bulk orders. But the manufacturer you’ve chosen won’t let go easily, especially if you’re of interest to them. The LOI gives them the right to raise prices as they see fit.

Working with independent rapid prototyping companies keeps your options open. You will have an opportunity to look for more cost-efficient and advanced ways to make your product in the future.

A manufacturer will, in most cases, own your technical documentation. For example, if they created 3D models using the sketches you provided, then automatically the latter becomes their intellectual property (IP). Unless you sign a Work for Hire contract with them. We had customers who first went to a manufacturer, and later in the process decided to work with us. Oftentimes they couldn’t get any of their technical documentation back from the manufacturer, so they had to start from scratch.

Working on the product development and invention prototyping at LA NPDT, we always find new aspects and nuances. And in many cases, our team comes up with new features or even inventions in the process. Consequently, we have our clients asking who would own rights on that intellectual property. Our answer is you, the client.

Unfortunately, manufacturing companies tend to have a biased approach to building a prototype. Instead of creating a product that you envision, the one that will benefit the end-users, they want the design to meet their manufacturing capabilities. In general, manufacturers are not creative thinkers but they are masters of systematic, well-organized, and template production. So, it doesn’t serve them to waste their resources “babysitting” your invention prototype development.

Rapid prototyping companies and product development teams, on the other hand, are there to walk you through the whole process using an individual approach to every inventor. At least, this is our way. We creatively collaborate with you as an integral part of our team, and by working back to back engage you in the process. Together we’ll put our time and efforts into increasing the market potential and viability of your product idea.

Unwavering commitment to our clients and our processes drive LA NPDT to strive for perfection on every prototype. Some of the best minds in the industry work hard to guarantee impressive results, delivered on time, every time. Unlike other rapid prototyping companies, we understand the pressures involved in bringing your product to life.

That is why our product development and rapid prototyping teams work together, under one roof. Having your rapid prototyping company in a single location provides you with peace of mind and an unmatched level of service.

Our experience in many industries allows us to design your product prototype with both manufacturing and marketing in mind. We focus on your target market and position you to easily sell your product.

At LA NPDT, we specialize in the rapid prototyping of medical devices, ensuring precision, functionality, and compliance with industry standards.

As an FDA-registered facility, we are equipped to prototype and manufacture products that require FDA certification.

Our team leverages advanced technologies and materials to create accurate prototypes that facilitate effective testing and validation.

Whether developing diagnostic tools, wearable health tech, or surgical instruments, we prioritize user safety and ergonomic design, delivering prototypes that help bring innovative medical solutions to life.

• Mechanical tools, devices, and machines
• Electro-mechanical machines
• iOS and Android mobile apps
• Chemical formulations
• Electronic devices, wearable gadgets, and IoT equipment
• Medical devices
• Silicone rubber products
• Fabric products and clothing
• Plastic consumer and industrial products

Before building any physical product we create a “virtual prototype”, a 3D CAD model. While creating the computer model, we consider how your product will appeal to your audience. We then explore material choices for the ideal look, feel, and function. Once we understand how the product is expected to look and work, we can begin developing and building it.

Our rapid prototyping company has machinery required for building a prototype with capabilities not only in the US but overseas as well.

PROTOTYPE PORTFOLIO

• Help to define and improve your idea
• Develop it
  
• Design it
• Build prototypes
• Manufacture the final product
• And introduce it to the market

That is why we truly understand all aspects of the process, which enables us to deliver the best version of your product going all the way from A to Z.

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When working with us, expect a very interactive process. For instance, if we’re building a prototype for your product, then after each revision, and sometimes in between, we show you the prototype to receive your initial feedback. 

Keep in mind that the invention prototype is usually a rough version, so it won’t look like your final product (manufacturing sample) eventually will. If you can’t meet with our team in person, then we communicate via video calls and send you the prototype via mail. You will then be able to touch and feel your idea physically.

You are always involved with us and the process through meetings and/or conference calls. There we discuss all the details and specifics of your project. We are tech, engineering, and marketing experts, but you’re the one who created the idea. Therefore, your big vision is important every step of the way.

Some product developers don’t really want to be involved in the process and it’s fine with us. Our team will put all our expertise into making your invention prototype the way you see it, to give the result you want. But based on our years of experience, we know that close collaboration between the inventors and the rapid prototyping companies brings the best results.

Being our customer, our team member, you have the ability to maximize the value of your prototype. You do it by bringing as much information as you can to us. Words and schematics sometimes are not enough. Therefore, we suggest you look for examples and research the market for some similar products that you like or don’t like. Find the products that have features close to the ones your product has. 

Please share those references with us. This way our designers and engineers can get a deeper understanding of your vision. They will pinpoint how your product should/shouldn’t work, look, behave, thus bringing more value to your invention prototype.

Also, you can present your produt prototype to your potential customers through media or other means, as we discussed earlier. This way you can get early feedback and lots of information from your future end-users. That will significantly influence the prototype’s efficiency and performance. It will enable you to optimize your product for the consumer as well.

One of our clients, Wayne Nix, the inventor of Multinix, when working with us, had personally interviewed over 200 nurses. He presented his prototypes to them and observed their response to every next version of the prototype that went through design iterations. It was very helpful. 

See MultiNix in our Portfolio

 Our rapid prototyping services will help you:

• Prove your concept
• Convey your ideas, requirements, and vision easier and faster
  
• Raise funding by demonstrating your product as opposed to talking about it
• Improve your design faster and in ways not possible without having a physical model
• Save money on manufacturing by allowing us to figure out the steps, equipment, and time necessary for product assembly

Our services go beyond just creating a prototype or a product. LA NPDT’s talented team of engineers, project managers, designers, and marketing experts will help you fine-tune your design, prepare it for production and market. We work to understand your idea and conceptualize what you are looking to produce, using an iterative process to develop your final product.