Effective Prototyping Strategies For Engineers

Stop waiting weeks for prototypes! build, test, learn, repeat. FASTER! Story time... I needed to make some thin gauge sheet metal parts. for prototyping, the dimensions and tolerances are not figured out yet. I just need to see if this idea works. I sent out the files to a few different vendors and got 1-3 week lead time... I ain't got time for that. if I wait around for two weeks and find out it's a bad idea, them I've just lost two weeks. with SendCutSend.com I can have flat laser-cut parts in a few days! (Protolabs , Protocase and Xometry are also viable quick-turn sheet metal vendors that provide simple bending ops) while my parts are being cut, I can design and #3Dprint some forming dies using Formlabs GrayPro resin, and pressed in alignment dowels from McMaster-Carr that I had on hand flat parts show up and I have functional prototypes in 3-4 days. (PRO TIP) because I ordered flat parts, I can print a few different variations on the forming dies and play around with the same flat parts to find the geometry that works the best. BUT WHY DO WE CARE ABOUT SPEED? is it because we're impatient? no it's because we can't buy the schedule back once the time is gone... and if you are designing something new to the world, the faster you can disprove your assumptions, the faster you can find ideas that work. the faster you find ideas 💡 that work, the faster you can get to testing the faster you get to testing the faster you get user feedback and user feedback is the holy grail in product development. people do weird and unexpected things with our products and so it's best to learn what they are going to do with it get out there and build something! #3dprinting #additivemanufacturing #rapidprototyping #design #engineering

What's the right number of prototype iterations in MedTech? Hint: the answer is not 1. That's like expecting a hole-in-one on a long distance golf shot. Just ain't gonna happen. Instead, focus your prototype iterations on answering specific questions: ➡️ Prototype 1: Does it work on the bench? Simplified proof-of-concept prototype that addresses key questions related to technical performance. ➡️Prototype 2: Does it work (pre)clinically? Early prototype aimed at collecting data, preclinically (for significant risk devices) or clinically (for non-significant risk devices). ➡️Prototype 3: Will people use it correctly? Usability prototypes (or mockups) aimed at evaluating user interfaces, usability, and possible misuse through human factors studies. ➡️Prototype 4: Does it achieve target COGS? Alpha prototype integrating industrial design and engineering, while designing for production materials and processes. ➡️ Prototype 5: Does it meet the requirements? Beta prototype addressing shortcomings of Alpha, and used for engineering verification testing (before V&V). So, minimum.. 5 prototype iterations. Often many more. Stage these prototype iterations so that each one gains the benefit of the prior. If you isolate these risk factors, your prototypes can be much simpler, faster and more cost effective to design, produce, and test. Prototyping is a mindset -- it's about learning, quickly and effectively. > Identify the right questions to answer > Build simple prototypes focused on the key questions > Run the tests, learn, and iterate. #medtech #medicaldevices #prototyping

Ever notice how "we need to prototype this" means something completely different depending on who says it? The confusion around prototyping isn't just semantic - it creates real friction when teams think they're aligned but are actually solving for different outcomes. So, I decided to start being more explicit when I tell our team that we need to prototype something. These are the four main buckets. Function First Prototyping explores technical capabilities and boundaries. We're asking: "What can we accomplish with this technology?" This might be testing an LLM's ability to process medical histories or exploring voice AI functionality. Message First Prototyping validates value propositions. We're asking: "Does this resonate with our user/buyer?" It's about crafting messaging and concepts to test market interest before significant development. This is where people should spend more time IMO. Form First Prototyping examines how people interact with a product. We're asking: "How should users engage with this solution?" This works for both physical and digital products, gathering feedback on usability before building full functionality. Feasibility Prototyping determines if an idea can actually be executed. We're asking: "Can we build and scale this within our constraints?" It identifies technical roadblocks, data availability issues, or operational limitations early. The key insight I've gained: being intentional about what you're trying to prove or disprove dramatically improves prototyping efficiency. Teams waste precious time and resources when they build the wrong type of prototype for their most critical questions.