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Structural prototyping and the modern design process

Prototyping tools and 3D printers are getting more affordable each year.

Five flavor varieties of IHOP at Home successfully replicate the restaurant dispenser design while meeting retail requirements in 12- and 24-oz packages.
Five flavor varieties of IHOP at Home successfully replicate the restaurant dispenser design while meeting retail requirements in 12- and 24-oz packages.

Whether or not to invest in one is a complicated equation. Before you even get that far, it’s important to know what roles prototyping should play at each stage of the design process.

1. When do you need prototyping? Are you trying to get consumer feedback? Are you trying to ascertain technical viability? Or is it for internal use only? Are you looking for rapid prototypes to provide better internal communication and consensus? Or are you trying to test a new packaging shape on production, labeling, or filling lines?

2. Where are you in the design process? Early in design exploration, you probably don’t need prototypes. Sketches and rough mockups actually have advantages over prototypes in that they can filter through more ideas in shorter time—and separate the wheat from the chaff. What you can learn, and what is the most efficient way to learn it, is different at each stage of the design process. Having the appropriate tactile stimuli for testing each use context is a learned art.

3. How can you make the process efficient? Ask a lot of questions up front. Determine the objective of the particular prototype that your staff or a client is requesting. Always start with solid shapes because they are less expensive and will allow you to explore the basic feel of products and packages. Hold off on high-end functionality until you narrow down the options to a few strong possibilities.

4. Is it a visual or a functional prototype? There’s a pretty easy line to draw between a “visual” prototype and a “functional” prototype. However, many customers expect the first prototypes to be both “looks-like” and “works-like,” which is almost always not reasonable. Visual prototypes can be used for sales presentations or photography, but functional attributes should be tested with unpainted durable materials such as SLA, SLS, Objet, or Starch models.

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