Prototyping is an early stage product development. Typically it is the first ideas that become physical objects. It is an opportunity to test functionality, form, and manufacturability.
In sheet metal fabrication, prototyping involves creating a small number of units i.e. one to ten typically just for evaluation and testing. This allows engineers and designers to identify potential issues in design, tolerances, or material selection before mass production.
Why Prototype:
- Risk Reduction: Discovering design flaws
- Design Iteration: Need to tweak the angle, cutout size, or fit
- Testing Fit & Function: Whether it’s verifying tolerances for assembly or checking aesthetics, prototypes are a test run.
- Test Tooling: Ideally there is enough confidence in the design to use “production tooling” to make the prototypes.
We frequently use technologies like laser cutting and CNC press brakes in the prototyping stage. But looking at these two technologies helps illustrate the cost difference of prototyping. CNC laser is relatively fast and efficient at cutting small quantity part runs. A CNC press brake takes easily 0.5 to 1 hours for set up and may well scrap 1-3 parts before getting the exact form desired if complex.
Moving to Production
Once a prototype lot tested, tweaked, and approved, it’s time for production. This involves producing larger quantities of the part(s) consistently and efficiently, with focus on repeatability and cost effectiveness.
At Seaborn Manufacturing, our metal fab shop is equipped to handle both short runs and high volume production. We leverage automation and advanced production planning.
Key Considerations:
- Tooling and Setup: Full production may require dedicated fixtures, or tooling was not used in prototyping.
- Material Sourcing: Bulk orders mean material selection and sourcing become critical. Lead times, costs, and consistency must be managed.
- Quality Control: With larger volumes, quality assurance processes are scaled to catch defects early and maintain output consistency.
Comparing Prototyping and Full Production
| Feature | Prototyping | Full Production | ||
|---|---|---|---|---|
| Quantity | 1–10 units | 100s to 1000s+ | ||
| Cost per Unit | Higher | Lower | ||
| Flexibility | High | Lower | ||
| Tooling Required | Minimal or TestProduction Tooling | Often required | ||
Choose the Right Path for Your Project
Ask yourself these key questions:
- What stage is my product in?
If you’re still refining the design or testing use cases, start with prototyping. - Do I need scalability right now?
Full production is the way to go if your product is finalized and demand is high. Also, production is a good choice if confident in the design and demand is limited. - What is my budget?
While the cost per unit in prototyping are higher, it’s a safer investment upfront. Production becomes more cost effective at scale. - Time? Do you have time for a prototype run followed by moving to production.
The Role of Technology in Modern Fabrication
Advancements in sheet metal fabrication have slightly blurred the lines between prototyping and production. Precision processes like laser cutting, CNC tube forming, precision press brakes and 3D modular weld systems have enabled manufacturers like us to offer hybrid solutions. Prototypes that easily scale to production with minimal changes.
Our metal fab shop was built on our ability to adapt quickly. From a prototype to full scale production runs, we have the tools and experience to support you through the whole product life cycle.
Comparing Costs:
One if not the most significant difference between prototyping and full production is in the cost structure.
Cost Per Unit
During prototyping, the cost per unit is much higher than in production. Why? You’re paying for all the development and set up (maybe little less tooling and fixture expense) and amortizing that expense across far fewer parts. Meaning those costs are concentrated across just a few units.
For example, a single prototype produced via sheet metal fabrication—using processes like laser cutting and press brake — may cost $300 to $600 per part depending on complexity. That same part, once it enters full production, might drop to $15–$60 per unit when produced in batches of several hundred.
Strategic Tip: Invest in Prototyping to Save on Production
Think of prototyping as an insurance policy. Spending a little more up front to ensure your design is tested and validated before you commit to high volumes.
By working with a trusted metal fab shop like Seaborn Manufacturing, you can optimize both phases—keeping your upfront investment lean while setting the foundation for scalable, cost-efficient production.
Conclusion
Both prototypes and full production run play a vital part in the product lifecycle. Knowing which to use and how to transition between them can significantly impact your project’s success. It is not all one or the other. Limited production runs are often used as the first, or intermittent step to full scale production. At Seaborn Manufacturing, we specialize in bringing our clients ideas to the world through whether they are sheet metal fabrication, tube bending, CNC machining, welding or combination of services. We typically help our clients straight through from prototype to full product launch. Seaborn Manufacturing with our clients every step of the way.