Examining Product Design and Prototype Development

Why does prototype development matter so much?

Prototyping is a crucial step in product development, allowing companies to test and refine their designs before mass production. This process does much more than simply identify potential flaws:

• Clarity: The most detailed technical drawing and appealing design do not guarantee a functional product. A prototype can provide evidence that the product is ready for the market – or not.
• Customer feedback: You can rave about the benefits of your product, but surveys and market analyses are key. However, nothing replaces a test under realistic conditions. You can gain valuable insights by showing the prototype to customers. It will highlight their needs and requirements and point out some aspects that you may not have considered.
• Onboard investors: The production of physical products is often associated with excessive costs. In addition to customers, investors are also an important target group. An effective and well-designed prototype shows that you know your “craft” and that an investment in your start-up is worthwhile.
• Cost savings: Since you’re already going through the production processes while developing your prototype, use the experience gained to save time and money –the keyword here is material consumption.
• Product optimization: By nature, prototyping is there to optimize your product.  You can still make some changes at the early stage of production. Later, it will cost you time, money, and effort.

What are the different approaches to prototyping?

There are several types of prototypes, each serving different purposes:

• Virtual prototypes: these are digital computer models developed with 3D CAD software. Digital prototyping is only successful if the relevant data is available and accessed across all phases of product development.
• Technical prototypes: this variant already has all the relevant features and functions of the intended product. The design and materials used correspond to the planned series. Technical prototypes are usually for extensive tests that highlight early-stage issues.
• Design prototypes: these are also referred to as design samples and are like the planned product in terms of appearance and ergonomics. The weight, the feel, and the coloring are also realistically reproduced with the design prototype.
• Laboratory samples: while this prototype contains all the mechanical or digital functions of the product, it still has an entirely distinctive look. The exact dimensions of the product, the surface coating or the design do not play a role in this prototype variant. On the contrary, the purpose of this variant is to check whether the prototype works flawlessly from a technical point.

Ideally, you would use a PLM platform to develop a virtual prototype as it can be manufactured at a small cost and include variants. The PLM platform also enables cross-disciplinary and cross-departmental development that involves multiple people from various areas. However, choosing the right type of prototype will depend on your budget, timing, and knowledge.

Key first steps in effective product design and prototyping

Effective product development begins with understanding user needs and conducting thorough market research. This involves gathering and analyzing customer feedback to guide the design process. Ideation and concept development follow, where creative solutions are brainstormed and evaluated.

Understanding user needs and market research

Understanding your target audience is vital. Conduct surveys, interviews, and focus groups to gather insights into customer preferences and pain points. This information will inform the design process and help tailor the product to meet market demands.

Ideation and concept development

During the ideation phase, teams generate a wide range of ideas and concepts. This creative process is essential for exploring different design possibilities and selecting the most promising solutions for further development.

NPI (new product introduction)

Before they start, the designer needs to know exactly what’s required from the new product. The design specification details this requirement in a formal document and should define what’s expected of the product’s functionality. But it won’t necessarily define how the product should achieve this.

Advantages of simulation and virtual prototyping

Simulation and virtual prototyping are invaluable in modern product development, offering significant benefits such as cost savings and the ability to test multiple design iterations quickly.

These tools allow for the visualization of a product’s performance under various conditions, enabling designers to make informed decisions before creating physical prototypes. By integrating MBSE (model-based systems engineering) and virtual twin technology, the product development process can be further enhanced.

MBSE (model-based systems engineering)

MBSE (model-based systems engineering) is a methodology that uses models to support the entire lifecycle of a system, from conception and design to verification and validation. Unlike traditional engineering methods that rely on text-based documents, MBSE employs digital modeling and simulation to design systems. This approach offers several advantages:

• Improve collaboration: MBSE’s visual and interactive models help diverse stakeholders understand and contribute to the development process, reducing misunderstandings and errors.
• Efficiency and cost reduction: by enabling early detection and correction of issues, MBSE can significantly reduce development time and costs. It allows for rapid iteration and facilitates automation, which is particularly beneficial for complex systems.
• Single source of truth: MBSE provides a centralized model that ensures all stakeholders work with consistent and up-to-date information, enhancing traceability and decision-making.

Virtual twin technology

Virtual twins are digital replicas of physical products or systems that simulate their behavior in real-world environments. This technology extends the capabilities of traditional simulations by offering a dynamic, real-time representation of a system. The benefits of virtual twin technology include:

• Risk-free testing environment: virtual twins allow for extensive testing and validation in a virtual space, reducing the need for costly physical prototypes and enabling exploration of a wider range of design options.
• Enhanced product insights: by simulating real-world conditions, virtual twins provide deeper insights into product behavior, allowing engineers to optimize performance and identify potential issues early in the development process.
• Integration with real-world data: virtual twins can incorporate data from products in operation, enabling continuous improvement and adaptation to changing conditions.

By combining MBSE and virtual twin technology, organizations can achieve a more robust and efficient product development process. These methodologies support the creation of innovative, high-quality products while reducing time-to-market and development costs.

What is the lean startup methodology?

The lean startup is a model companies use to efficiently establish their foundations and plan their product or service development process. The aim is to go to market as quickly as possible while getting customers’ feedback. This then leads to further development of the startup or product. Frequent testing of the product properties is just as much a part of this method as is the constant adjustment of prices, sales channels, or design elements.

Working quietly on a product for years before launch is something you want to avoid, and involving customers, suppliers, or investors throughout all stages of the production process is key. Lean Startup is more about a constant evolution that gradually perfects the product than it is about a finished creation.

BML (build-measure-learn)

This concept is at the core of the lean startup model.

• Build: develop the product prototype. You may well have the courage to leave gaps. Perfection is not possible here, nor is it the goal.
• Measure: get your prototype tested by real users who should fall into your target audience.
• Learn: analyze customers’ feedback and gather valuable information that you can then use to optimize your product.

Note, this is not a one-off box to tick. Run through these three phases all over, again and again. That way, you can continuously improve your product and adapt it to fit the needs, expectations, and wishes of your target groups. The build-measure-learn concept is linked to the MVP (minimum viable product), so let’s explore that in a little more detail.

Minimum viable product

Another way to put the lean startup method into practice is to develop a MVP (minimum viable product), a first simple version of the product with no sophisticated design elements or additional features. Add these gradually once your MVP has been on the market for a while, and you have had enough customer feedback. The development of this basic product is very cost-effective, and its price-performance ratio is correspondingly attractive for customers. You can then add more complex unique selling points based on their feedback.

Compared with the BML model, no prototype is developed here, but a simple version of the product. However, the advantages of this approach also lie in low production costs and targeted development tailored to the needs of potential buyers.

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What can OEMs learn from lean startups?

OEMs (original equipment manufacturers) can benefit from the lean startup approach by adopting its principles of validated learning and iterative development. This methodology helps OEMs quickly adapt to market changes and customer feedback, ensuring their products remain relevant and competitive.

Accelerate product development

Startups often want and must bring a usable product to market as quickly as possible. It is the only way to ensure liquidity and further growth. With the Lean Startup model, you can focus on the essentials and, thanks to lean processes, develop and market your product in record time.

Lower costs

The short development time reduces costs due to the simplicity of your product (less material). Targeted product development: You know which features your product must have based on customers’ feedback gathered over time. The risk of expensive mistakes is reduced, and your product undergoes continuous evolution. You can also increase your price and benefit from a better margin in the medium-long term.

Real innovation advantage

Customers feedback helps you identify trends and developments before the competition. The analysis of customers’ needs and their influence on development ensures that your product is ahead of its time and correspondingly popular.

How can TECHNIA help?

We offer a range of tools and services to support startups and established businesses in their product design and prototyping journey. We help clients streamline prototyping processes and bring innovative products to market efficiently, with a wealth of experience in deploying unique digital engineering software and services. Our team works closely with clients to understand their unique needs and deliver tailored solutions that drive success.