Prototype Manufacturing

Prototype development occurs throughout the product design process, both at the beginning to check on shape and comfort, and at later stages to test technical feasibility and design details. Product prototypes give the client and focus groups or test customers an idea of the functionality and look of the product before mass production begins.

At Brooks Stevens, we pride ourselves on creating a final product prototype that is so detailed, most consumers wouldn’t be able to tell the difference between the prototype they’re holding and the final product on store shelves. But before the product prototype reaches that final product, it goes through a variety of stages.

Early-Stage Product Prototypes

Early prototype manufacturing is often done by hand by an industrial designer. They are typically carved out of a lightweight foam and used to imagine the shape of the product. As the early product prototypes progress, they become more detailed, first including drawn-on features, then finally carved features. These models are used to both help the industrial designer throughout their process, but also to help the engineer once the project is transferred to them. They are able to comprehend the designer’s 2D sketch by analyzing the 3D prototyping provided to them.

Late-Stage Product Prototypes

Later prototype manufacturing is often done by machine in order to provide a more thorough level of detail. These late stage product prototypes maybe 3D-printed or created out of other forms of plastic modeling. In order to provide even greater detail, different types and colors of plastic may be used to test different parts of the user experience. The most advanced product prototypes are created by a manufacturer and function as the product would when at market.

Detailed Final Prototypes

Brooks Stevens prides itself on creating detailed and complex final product prototypes that are nearly indistinguishable from the final product on store shelves. By utilizing a variety of plastics, color matching paint systems, silicone molding, and more, Brooks Stevens’ prototypes can be complex replications of the product that will eventually grace store shelves.

Our prototyping lab is full of a variety of machinery that allows us to create detailed prototypes throughout the industrial design process. We provide the following services to our clients:

  • Visual Models
  • Functional Mockups
  • Pre-Production Runs
  • CNC Machining
  • Metal Fabrication
    • MIG
    • TIG
    • Acetylene Welders
  • Silicone Modeling
  • Urethane Part Casting
  • Proof of Concept Models
  • Full-Function Prototypes
  • Vacuum Forming
  • Rotational Modeling
  • Fiberglass Fabrication
  • Custom Painting: 10’ Boot, Sikkens System for Color Matching
  • Label & Packaging

Would you like to put one of our highly-detailed product prototypes to the test? Contact us today to learn more about our prototype manufacturing capabilities.