What is a Prototype and Techniques?
Explore prototype engineering techniques, from low to high-fidelity prototypes, and rapid prototyping methods for product development.
The journey from an initial concept to a fully realized product involves a meticulous and multi-stage process known as the engineering product development process. This comprehensive cycle is critical in transforming innovative ideas into market-ready products. The phases of this process include proto engineering, Engineering Validation Testing (EVT), Design Validation Testing (DVT), Production Validation Testing (PVT), and Mass Production (MP). Each stage plays a pivotal role in ensuring the final product meets all design, functionality, and market requirements.
The engineering product development process begins with conceptualizing and designing the product. This phase is where the foundation for engineering product design is laid. Engineers and designers collaborate to create a detailed blueprint of the product, focusing on aesthetics, functionality, and feasibility. The initial design phase also includes extensive market research to understand consumer needs and preferences.
Following the conceptual phase, the first tangible step is proto engineering. A prototype, also known as EP (Engineering Prototype), is built. This stage involves creating a low-quantity (typically 1-10 units) run of the product, combining engineering and design to produce a Minimum Viable Product (MVP). In this phase, leverage off-the-shelf components to construct a foundational architecture and validate core functionalities. A prototype, built using these components, will serve as a testing ground for design iterations and performance evaluations. The resulting parts and model database will be instrumental in obtaining cost estimates from manufacturers through RFQs.
Once a working prototype is developed, the next phase is EVT engineering. EVT involves creating a batch of 10-30 units to ensure that the product meets all functional requirements outlined in the Product Requirement Document (PRD). This critical stage involves developing custom hardware, such as PCBs, injection molded, sheet metal, and die-cast components, to create prototypes that closely resemble the final product. By combining aesthetics and functionality, EVT validates the design’s feasibility. Engineers collaborate closely with manufacturers to oversee assembly, ensuring the product can be efficiently produced using specified materials and processes.
During EVT, up to 40% of units may fail due to various reasons, highlighting the importance of rigorous testing and analysis. If significant design flaws are identified, an EVT II build may be necessary to address these issues. The EVT phase is essential in the engineering product development cycle as it allows engineers to refine and perfect the product design before proceeding to the next stage.
With hardware finalized, the project transitions to Design Verification Test (DVT). This phase focuses on optimizing manufacturing processes and ensuring the product meets aesthetic and environmental standards. Using production-intent tools and components, a batch of 30-200 units undergoes rigorous testing, including durability, drop, and water resistance assessments, as well as extensive battery evaluations. DVT units should closely mirror the final product, validating the manufacturing readiness, Industrial design finishes and overall product quality.
DVT is also crucial for products that require regulatory certifications such as FCC or UL. This phase marks the final step before the units are deemed suitable for sale. By the end of DVT, any issues causing unacceptable yields should be resolved, ensuring that the product is ready for mass production engineering.
PVT testing is one of the most exciting stages in the engineering validation process. During PVT, the first official production run is conducted, typically comprising 5-10% of the first production run’s volume. This phase verifies that the product can be manufactured at the required volumes and target cost. The units produced during PVT are expected to be market-ready and suitable for sale.
PVT is also the stage where QA (Quality Assurance) and QC (Quality Control) procedures are developed. These procedures enable manufacturers to identify and rectify any failures throughout the manufacturing process. As products come off the assembly line, it provides the final opportunity to make any necessary adjustments to the tools and processes before full-scale production.
The final stage of the engineering product development process is mass production engineering. This stage involves ramping up production to meet market demand. It is often divided into three sub-stages based on maturity: red, yellow, and green. The red stage marks the beginning of mass production, where the production line starts but is not yet operating at full efficiency. The yellow stage indicates that production has been ongoing for some time, with optimizations being tested and yield improvements being made. Finally, the green stage represents a well-oiled production machine, where yield opportunities plateau, and continuous process improvement becomes the main focus.
During mass production, design efforts are minimal, with the primary emphasis on maintaining high production quality and reducing costs through continuous process improvements. This stage ensures that the product reaches consumers in its best possible form, meeting all design and functionality specifications.
The EVT DVT PVT processes are integral to successful product development. They provide a structured approach to identifying and resolving design and manufacturing issues early in the development cycle. By catching these issues early, companies can avoid costly mistakes that could arise from manufacturing thousands of unusable units.
EVT, or Engineering Validation Test, ensures that the product design meets all functional requirements. It involves rigorous testing and analysis to identify and rectify design flaws. DVT, or Design Validation Test, focuses on refining the production process and ensuring that the product meets all cosmetic and environmental requirements. PVT, or Production Validation Test, verifies that the product can be manufactured at the required volumes and target cost, with a focus on developing QA and QC procedures.
These structured processes help companies ensure that their products meet all design, functionality, and market requirements before full-scale production begins. This approach minimizes risks and ensures a smooth transition from concept to market-ready product.
Engineering design and testing are at the heart of the product development process. From the initial concept to the final product, each stage involves meticulous design and rigorous testing to ensure that the product meets all specifications. This process involves multiple iterations of design, prototyping, and testing, with each iteration bringing the product closer to its final form.
The engineering product development process begins with detailed engineering product design, focusing on aesthetics, functionality, and feasibility. This initial design phase includes extensive market research to understand consumer needs and preferences. Once a prototype is developed, it undergoes rigorous testing during the EVT, DVT, and PVT phases. Each phase focuses on different aspects of the product, from functionality to production processes, ensuring that the final product meets all design and market requirements.
The engineering product development process is a comprehensive cycle that transforms innovative ideas into market-ready products. By following structured processes such as proto engineering, EVT, DVT, PVT, and MP, companies can ensure that their products meet all design, functionality, and market requirements before full-scale production begins. This approach minimizes risks, ensures high production quality, and reduces costs through continuous process improvements. Through meticulous engineering design and testing, companies can bring high-quality products to market, meeting consumer needs and preferences.
Explore prototype engineering techniques, from low to high-fidelity prototypes, and rapid prototyping methods for product development.
A minimum viable product (MVP) for hardware is about finding the fastest path to generating revenue.
Discover the key stages of engineering product development, from concept to mass production, ensuring market-ready, high-quality products.
