Design, build, test and improve
Developing a prototype: from idea to testable product
A prototype makes your idea tangible. It helps to evaluate technical choices, gather user feedback and justify the next investment. PEZY helps startups, scale-ups and established companies learn efficiently with models, functional prototypes and pilot runs. We select the approach that fits the questions you want to answer.
These companies rely on PEZY to turn their product into reality.
What is a prototype?
A prototype is a visual or functional development of a product idea. You use it to investigate what works, what is still missing and which choices need to change before you invest in tooling or mass production. An attractive model does not automatically prove that a product is technically or commercially feasible: the testing objective determines what evidence you can gather with it.
Spot risks earlier
Discover technical issues, usability problems and manufacturability bottlenecks while changes are still relatively easy to make. A prototype helps to better prepare investments in production tooling.
User feedback
Let people hold and operate a model. Observations and targeted tests reveal whether the shape, ergonomics and controls meet their needs.
A concrete story for stakeholders
A tangible demonstration makes an idea discussable with customers, colleagues and investors. It supports a well-founded decision, without being a guarantee of funding or market success.
Targeted iteration
With successive models you compare solutions and improve the design. Simple iterations can be carried out quickly; complexity, material and technique determine the actual lead time.
Investigating manufacturability and cost
A representative prototype provides insight into assembly, material usage and production bottlenecks. For a reliable cost estimate you also need volume, tooling, process and supplier information.
Preparing testing and validation
With a sufficient number of representative prototypes, relevant safety and performance tests can be prepared or carried out. We tailor the test setup to the product and the applicable requirements.
From simple mock-up to pre-production prototype
Not every development phase requires a fully working product. Start with the simplest version that answers your question and increase the level of detail intentionally. This keeps costs and effort proportional to what you want to learn.
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Low-fidelity: form and initial use
Foam models, cardboard or basic 3D prints make dimensions, layout and ergonomics visible. They suit early concept decisions. Simple mock-ups can sometimes be produced within a few days; we set the schedule based on the assignment.
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Medium-fidelity: realistic appearance
Higher-quality 3D printing, CNC machining or vacuum casting brings the model closer to the intended form and basic functionality. This supports user research, design validation and presentations to stakeholders.
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High-fidelity: functional testing
Mechanics, electronics, software and representative materials come together in a working model. It is intended for technical validation, performance testing and use in realistic conditions. The Protolab and the Pilot Factory support this development.
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Pre-production: testing the manufacturing process
Pilot or validation prototypes are made using the intended production technique, for example injection moulding with rapid tooling. This allows us to assess tolerances, assembly, material properties and cost before scaling up.
Our approach to prototype development
Design, engineering, prototyping and rapid tooling are integrated. Lead time depends on complexity and the validation questions. A programme of a few weeks, for example two to eight weeks, can be feasible for a well-defined assignment; we first prepare a project-specific schedule for that.
Why PEZY
Why develop a prototype at PEZY?
At PEZY, industrial designers, engineers and prototype builders work closely together. In the Protolab and the Pilot Factory we can build, test and adjust models with short lines between design and execution. That reduces handover moments and keeps the learning from the prototype within the development team. With more than thirty years of experience in medtech, consumer products and industrial applications, among others, we also look ahead to manufacturability, assembly and circularity. The prototype is therefore not separate from later production.
3 locations
Design, engineering and production working closely together.
Pilot Factory
From first model to small series, in-house.
30+ years
Product innovation since 1995.
Great Place to Work
Recognised based on feedback from our employees.
Make your product idea tangible
In an initial conversation we map out your idea, uncertainties and preferred next step. A more in-depth Break Through Session can help identify challenges and set a direction. We align the format, duration, schedule and cost estimate to your needs. Whether you want to explore a first concept or validate a product line: we will think with you about an appropriate approach.
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