For the past three weeks, I have been building a prototype of a product I invented a few months ago. I started with paper and cardboard templates, then moved on to steel, a material closer to the target. Colleagues reminded me how to use the riveting machine and taught me how to make changeover the hand press. Each successive attempt showed what didn’t work and inspired further solutions. Ultimately, the prototype placed on the testing machine confirmed, that the hypothesis was right. Is this a product that will enter the company’s product catalogue? At this stage, I don’t know.

It’s been a long time, since I’ve done this (physically building prototypes) and I’d forgotten how satisfying, learning and inspiring the process is. I have reserved time in the next few weeks to build more. I can’t wait for that moment when I start a functional test and see, that what was still a sketch ‘yesterday’, works today and has a chance to be on the market ‘tomorrow’. I know I will learn a lot and even if one of the prototypes doesn’t work as I plan, it will inspire more ideas.

I have always been involved in the idea generation phases. I derive satisfaction from both generating ideas as well as exploring and applying different methods and tools to support creativity. 

I want to emphasize at this point that, working in R&D, I am always close to prototypes, their testing and how they are manufactured. However, the difference between being close to this process and producing a prototype by hand is huge. 

I wonder. If this experience was so revealing for me, can it be so for others too?

This article is an encouragement to start working on your first prototype tomorrow, whether you’ve never done it before or you did it a long time ago and stopped for some reason. 

Below I describe some observations, that helped me to realize the prototype. I will be using them when building the next ones. Perhaps some of them will also help you. 

you don’t have to know how to design to build a prototype

Do you have an idea for a product but can’t handle any CAD software? Not a designer, not familiar with dimensioning and not quite sure what dimensional tolerance is? This is not an obstacle to building prototypes. All you need is a sketch, a visualization of an idea. A hand-drawn sketch, maybe some brief description of what the drawing shows, what parts need to be made and how they should be positioned in relation to each other. If the sketch doesn’t include something, don’t worry about it – it will all become clearer when you physically build the prototype.

organize the necessary space

It is good to have some place, where you can leave what you are working on and be able to come back to it. This could be a place on a table in the workshop, in the prototyping room or any other place, where you can leave what you are working on and no one will throw it away or destroy it by accident.

start as simply as possible

Don’t complicate the task at hand. Build your first prototype (non-functional) with materials that are easy to work with. This could be: paper, cardboard, string, wood, glue, plywood, staples, etc. These materials are easy to machine and connect. This first prototype is needed to find the right proportions between the parts. You can also check how the parts will move in relation to each other (kinematics) and thus determine the shape and size of each part. 

it’s good fun but use common sense

When you move on to working with near-target materials or those, that will allow you to build a functional prototype, you will most likely use power tools, presses or other equipment. Remember, that when performing these activities in the workplace, you need to be trained in how to use them (job and health and safety training). If you are not comfortable or have forgotten how a tool works – ask someone who uses it on a daily basis. Glasses and other adequate personal protective equipment are just as important, when working with tools at work and at home. 

ensure a budget – sometimes you have to buy something

It is worth making sure that in a situation where you need to buy some material or order an external service – you will have the means to do so. As a rule, the first prototypes cost tens or hundreds of EUR. Confirm with the person in charge of the budget, that you can count on such funds when you need them. 

show others what you have done and ask for feedback

Do not wait too long before showing the prototype to others for feedback. The sooner you get constructive feedback, the better the chance of faster optimization and reduced time to prepare a proper functional prototype. 

keep notes, document steps

I encourage you to document the next steps in building your prototype. I use power point, but any form will be helpful. A photo, a short video, a description of what worked, what perhaps needs to be changed in the next step. Every observation can prove valuable. 

don’t give up too quickly

The prototype doesn’t work as you planned? Its appearance does not encourage you to show it to others? Preparation takes longer than expected? Don’t know how to handle a device? All of these questions come in my mind when building a prototype. It’s perfectly normal for plans to be overly optimistic and for activities, you’ve never done to turn out to be more difficult, than you thought. Sometimes it helps to take a short break while building a prototype. Don’t forget that you are not alone. It is very likely, that there is someone in your immediate environment who can support you. 

look for uniqueness – there is certainly potential for a patent here

Have you never thought of yourself as an inventor? If you have started to build a prototype, it means, that you are on the path that all inventors once took. Even if it seems very unlikely to you, there is certainly the potential for a patent in what you are currently working on. Do you have no idea what this means and what the next steps in the patenting process are? In companies that have R&D departments, there is always someone to support you. If you don’t have that support, you can always try to do it on your own. If you are building a prototype at work, check that your employment contract does not regulate the intellectual property rights to your ideas. 

implementing one’s own ideas or those of others

Is it easier to implement your own ideas or those of others? I think it depends on individual predisposition. Personally, I prefer to realize my own ideas. However, if I were to build a prototype based on someone else’s idea, I would definitely want to have a say in its final shape. 

Summary.

You don’t need specialist skills to build prototypes – you just need an idea and some space to work with. Simple materials, tools and attention to safety are key, and perseverance through the rough patches can lead to innovative solutions. It is worth listening to the opinions of others, documenting progress and being open to the possibility of creating something truly unique, that can be validated by a patent.