Review what the prototype demonstrates
Check the design revision, build method and test results. Identify what has been verified and what still relies on an assumption.
Solutions / Prototype to Production
Prototype to Production: DFM, Tooling & Pilot Builds
It works as a prototype. What about production?
Turn a working prototype into a product you can manufacture consistently.
Discuss production readinessProduction readiness
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What has already been proven?
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What changes for the production process?
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See what the work involvesWhat needs a sample or pilot to verify?
Your starting point
You have a prototype or design. You need to know what is ready for production, what still needs work and how to move forward.
What needs to be proven before production?
Review the existing design and test results against the intended materials, processes, volumes and quality requirements. Focus the work on the gaps that matter.
A working prototype
Does it work?
A prototype tests the design, fit or function under specific conditions.
Repeatable production
Can it be made consistently?
Production also depends on materials, suppliers, tooling, assembly, cost and quality.
What needs to be ready?
Design & DFM
Does the structure suit the intended process?
Review the features that change with the production method: wall sections, fastening, tolerances and access for assembly. Agree which revisions need checking before release.
Materials & components
Are specifications suitable for repeat supply?
Confirm the required properties and component specifications. Where an alternative is proposed, identify the performance and quality checks needed before approval.
Tolerances & assembly
Can parts fit and assemble consistently?
Check interfaces and tolerance relationships, including any manual adjustment used in the prototype. Define a repeatable way to locate, join and inspect the parts.
Tooling
What tools or fixtures are needed, and how will they be verified?
Identify the mold, tooling and fixture work relevant to the product. Agree sample review, revisions and acceptance requirements before the next commitment.
BOM & documents
Is manufacturing information complete and consistent?
Align the current drawings, BOM, material specifications and approved changes. Make sure the teams preparing and checking the build use the same revision.
Suppliers & processes
Do capability and quality requirements align?
Review the proposed production route against the requirements. Clarify responsibilities across parts, assembly, inspection and testing, including existing suppliers.
Pilot production
Which questions need a representative trial?
Use a trial where production conditions need to be checked. Record assembly, process and inspection findings, and close the critical issues before proceeding.
Quality & repeatability
What evidence supports the next release decision?
Agree the critical requirements, measurement methods and acceptance criteria. Review the relevant sample or production findings rather than treating one successful build as proof of consistency.
Review the areas relevant to your product. Not every project needs every activity.
Examples of production decisions
Different gaps. Different engineering work.
- CNC prototype → molded part: review wall sections, draft, tolerances and fastening for the intended production process.
- Hand-fitted assembly → repeat build: review location features, tolerance relationships and assembly sequence.
- Prototype material → repeat supply: assess an available alternative and verify the required performance.
From assessment to implementation01 02 03 04
Prepare the engineering and tooling
Resolve the changes needed for the chosen manufacturing process. Confirm drawings, materials and critical dimensions before committing to tooling.
Build and review production samples
Review engineering samples, assembly and test results. Agree changes, update the documents and verify the revised parts before the next build.
Use a pilot to check repeatability
Run a representative trial where needed. Review the parts, process and inspection results, close critical issues and agree the basis for production release.
What to bring
- Existing CAD, BOM and prototype or sample
- Known test results and unresolved issues
- Target volumes, timing, materials and use conditions
What the work can deliver
- Production-readiness gap review
- DFM and engineering change priorities
- Tooling and pilot acceptance criteria
- Pilot findings, resolved actions and release recommendation
Have a prototype? Let’s discuss production.
Show us what you have and tell us what you need.
Discuss production readiness