Phase 2: Prototype Development

During the product development process a product must undergo a vital, comprehensive stage: Prototyping. The Prototype development phase is where validation of the engineering and industrial design work completed in phase 1 occurs. To begin, our mechanical engineering team works diligently to verify the product is designed for its intended use while meeting the essential requirements for proper functionality. Once the mechanical design has been completed, fabrication and assembly of the prototype take place so it can be extensively evaluated and tested. Each step within phase 2 plays a crucial role in the overall future success of the product. 

Before the product can be fabricated and tested, it must go through an extensive design process. Whenever parts are manufactured they are never perfect; even precise parts are not perfect. This inconsistency can compromise the ability of the product to operate or assemble properly. To minimize this risk, during mechanical design our engineers focus on how each part and assembly interacts with one another. This includes conducting a thorough tolerance analysis on each part and assembly. Performing these tasks provides us with assurance that the parts will always fit together and function correctly. 

Once we are confident we can move forward with our design, the next step is fabrication, assembly, and testing of the product. The overall objective for testing is to execute a detailed test and evaluation plan that will verify the engineering analysis and design that has been completed thus far. Some typical tests include:

• Shock and vibration
• Thermal testing
• Operational testing
• EMI/RFI
• Safety evaluations (UL, CE, CUL)

Once the results are compiled and analyzed, we are able to determine if any revisions will be necessary. This gives us a better understanding of what we will need to address in the next phase to further improve the design and prepare for production.

As detailed above, the prototype development phase is a significant period in the product’s development life cycle. It is imperative that each step is thoroughly addressed and given proper attention. Our ambition at DT Engineering is to design a sound product for our clients that will be reliable and profitable in its market for years to come. With over 30 years of experience in product development we are confident following our structured phase approach will yield a successful product.