From prototype to production: what changes and how to plan it
A working prototype proves the idea. These steps prove it can be made the same way every time.
- Prototypes prove function; production proves repeatability
- Lock the design with a formal sign-off before tooling
- Use a first article inspection to approve the production process
- Plan tooling, materials and inspection before volume
Why a prototype is not a production part
Prototypes are often made with processes chosen for speed, such as 3D printing or one-off machining. Production uses processes chosen for repeatability and cost at volume. A part that works as a prototype can behave differently when it is moulded, cast or machined in batches.
Step 1: Design for manufacture
Before production, review the design for the chosen process. Wall thicknesses, draft angles, tolerances and material choices that were fine for a prototype may add cost or risk in production. Small changes here save money on every unit.
Step 2: Freeze the design
Agree a revision of the drawings as the production baseline. From here, any change goes through a simple change control: what changes, why, and its effect on cost and timing.
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Step 3: Tooling and pilot batch
If the process needs tooling, it is made now. A small pilot batch shows whether the process produces good parts consistently, and gives you parts for testing or certification.
Step 4: First article inspection
The first production part is measured against every dimension and note on the drawing, and the report is signed off. This approves the process, not just the part.
Step 5: Production and batch inspection
Once approved, production runs to an agreed schedule. Each batch is inspected against the agreed plan before release, with records you can file.