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At SGW Designworks, we’ve seen over a hundred products move through the pipeline from initial concept to full-scale manufacturing. One of the most challenging (and important) stages is the transition from prototype to production. While a prototype proves that a concept can work, production requires that the design can be manufactured reliably, at scale, and at target landed cost.
Here are ten of the most common mistakes companies make during this critical transition—and how to avoid them.
1. Treating the Prototype as the Final Design
Prototypes are developed and built with for specific testing, with less emphasis on cost, manufacturability, or repeatability. Assuming that a “working prototype” equals a “production-ready design” is one of the fastest ways to run into problems.
2. Skipping Design for Manufacturability (DFM)
Design features that work in one-off prototypes can add significant cost, complexity, or risk in production. Failing to run a DFM phase of work before engagin manufacturers leads to edelays and re-work.
3. Overlooking Supply Chain Realities
Component availability, lead times, and vendor capabilities can make or break a product launch. Relying on parts that are hard to source can cause delays before production even begins.
4. Ignoring Durability and Environmental Testing
A single prototype might work in controlled conditions. But scaling requires robust testing: thermal, environmental, vibration, safety, and compliance. Skipping this step can stall production just as momentum builds.
5. Failing to Plan for Assembly
Prototypes are often hand-assembled by engineers. In production, labor costs and assembly speed matter. Poor assembly planning can increase unit costs and decrease quality.
6. Neglecting Tolerance and Fit Analysis
What fits perfectly in a prototype built by hand may not fit once manufactured at scale. Without proper tolerance analysis, assemblies may be difficult to produce efficiently, or fail prematurely.
7. Forgetting About Serviceability and Lifecycle
Products are rarely static. Battery replacements, firmware updates, and part swaps all matter in the real world. Overlooking lifecycle considerations during the transition to production creates costly redesigns later.
8. Underestimating Tooling Costs and Lead Times
Injection molds, stamping dies, and custom fixtures take time and money to produce. Companies often underestimate these factors, leading to unplanned budget spikes and schedule slips.
9. Skipping Pilot Builds
Skipping a pilot production run can feel like a way to save time and cahs, but it often results in large-scale failures. A controlled pilot run helps uncover issues before full investment in tooling and production.
10. Not Building the Right Team for the Transition
Prototype development success often comes from a small, agile team. Production success requires integration across design, engineering, manufacturing, and supply chain experts. Companies that don’t expand their team’s capabilities at this stage often stumble.
Final Thoughts
Moving from prototype to production is a pivotal stage in the product development journey. It requires a different mindset, broader expertise, and disciplined planning. At SGW Designworks, we’ve guided clients through this transition since 2008, helping them avoid costly mistakes and accelerate their path to market.
If your team is preparing to scale a product beyond the prototype stage, reach out to us. We can help you identify risks early, refine your design for production, and ensure your launch goes smoothly.
