It’s 2020. You walk into your cluttered garage, inspired and eager to work on your newest idea.

You lay out the materials and say to yourself, “Let’s build the first prototype.”

You glance at the array of tools and materials – cardboard, clay, 3D printer – and your mind races. “Umm…” you ponder, “Which material should I start with?”

You decide to pick the most cost-effective one. “What’s the best option to get started with?”

“Cardboard, undoubtedly,” your instinct replies.

What type of material do you end up choosing?

Today, we’re exploring key principles of physical product prototyping that every innovator should know.

This week, we’re dissecting the enigma that is the prototyping process — the cornerstone of physical product development that’s helping transform rough sketches into scalable successes.

Let’s dive right in…

1. Start with low-fidelity prototypes

Don’t spend time on aesthetics for early prototypes.

Use the quickest, cheapest materials possible like cardboard, clay, 3D printing, etc.

Focus only on essential elements like form, weight, and key features.

Low-fidelity prototypes allow you to test functional design elements and quickly gather user feedback without getting bogged down in perfecting details and surface finishes.

Build multiple rough prototypes and determine which direction shows the most potential before investing more time and money.

2. Identify and isolate the biggest risks

Carefully evaluate your product design to pinpoint elements with the biggest uncertainties and potential flaws.

• Is the grip comfortable for different hand sizes?
• Is the mechanism smooth and intuitive?

Build dedicated prototypes focusing only on those high-risk areas.

For example, prototype just the product’s handle with various shapes and textures to find the optimal ergonomic design.

By isolating risky components during prototyping, you can resolve issues efficiently before they become entrenched in the design.

3. Prioritize critical features

Determine the 2-3 most important features or differentiators that bring value to the customer.

Focus initial prototypes mainly on perfectly executing those features.

A baby stroller’s folding mechanism is far more crucial than the color scheme.

Prioritize prototyping and refining innovations that directly support your product’s purpose, before addressing decorative elements.

4. Design prototypes to answer key questions

Be intentional about which questions each prototype will help answer so you can extract maximum learning.

Identify assumptions and unknowns, then create models specifically to validate those points.

Some examples:

• How easy is the dispensing mechanism to use?
• Which handle design feels most sturdy?

Observe real users interacting with your prototypes and the feedback will reveal improvements needed in your product’s development.

5. Build, test, iterate, repeat

Prepare for an iterative loop of:

• Building prototypes
• Gathering user feedback
• Refining the design
• Rapidly re-prototyping

Be flexible rather than rigidly attached to your first idea.

Creating a culture of continuous experimentation prevents stagnating on a flawed prototype.

Expect to go through 5-10 iterations before reaching your optimal design.

Final thoughts

Smart prototyping is about learning fast and failing cheaply.

Maintaining an agile, iterative mindset allows you to rapidly test assumptions, identify issues early, and evolve your design informed by real user experiences.

Using these proven principles will ensure your product delivers maximum value to customers.