We sketched the production structure first, then built the prototype cheaply and quickly by a different process

The situation when the request came in

A prototype built from a rough concept existed, and the client wanted to raise it to a lighter prototype aimed at volume production. At the same time, they had no clear view of which structure or process would be used in volume production. Pushing ahead with prototypes while the production route is still unknown means rebuilding later. The question was how to avoid that rework while still moving fast.

What we did

We first put the volume-production concept on paper as a sketch, so that the structure we were ultimately aiming at was agreed up front. On that basis, we proposed building the prototype by a completely different process from the production one — keeping the intent of the production structure, while choosing a process that is cheap and quick at the prototype stage. Working to that plan, we took on both the prototype design aimed at volume production and the prototype sourcing as one engagement.

The outcome

We delivered the prototype in 1.5 months, and it cleared the pass criteria set in the client's testing.

What this project shows

Using different processes for the prototype and for production looks like a detour, but it is often the shortest path. Once the production structure has been sketched out, the prototype can be narrowed to only what you need to verify, and built cheaply and quickly.