Prototyping & rapid tooling
Prototyping and rapid tooling: from idea to tangible product
Prototyping makes an idea tangible and lets you test form, function and usability. Rapid tooling enables the step to small runs, so you can also assess assembly, material behaviour and performance. At PEZY we combine both: from the first model to practical testing and preparation for production.
These companies rely on PEZY to turn their product into reality.
What is prototyping?
From a digital design to practical proof.
Prototyping is the creation and testing of models to answer design questions before you invest in mass production. With a prototype we verify whether a function that works in a digital design also performs in practice. A functional demonstrator also makes a product innovation tangible for stakeholders and investors.
Before large-scale production begins, we test crucial decisions about functionality, aesthetics and composition. The testing objective determines how detailed a prototype needs to be and which characteristics it must represent.
A strategic step
A prototype at PEZY is never just a model. Where a digital design shows what is possible, a physical prototype shows what actually works. It is a concrete learning tool that guides the path to market introduction.
Design, engineering and production
Our teams combine industrial design, plastics engineering and manufacturing expertise. Designers work closely with engineers, materials specialists and production managers. We consider not only form and function, but also manufacturability, material choice and circularity.
Iterative development and validation
We develop and test multiple variants. Each iteration yields insights that allow us to improve the product step by step. By validating crucial decisions early, we reduce risks and prevent untested assumptions from carrying over to the next phase.
From form study to functional model
We might produce a simple form study using a 3D printer, for example. For the next test we develop a functional model and assess manufacturability, durability and assembly with our Plastics Factory. From simple models (low-fidelity) to detailed prototypes (high-fidelity) and pre-production models: each version answers different questions.
Testing materials early
Sustainability does not start at production. In this early phase we test how recycled or bio-based materials perform. This allows us to incorporate material behaviour into the design and investigate whether a choice suits the function and intended production route.
Designing for the next life phase
We explore how a product can be easily disassembled or reused at the end of its service life. This makes a prototype a step towards a scalable and sustainable solution, rather than merely a realistic representation of the final product.
Why prototyping is essential
Prototyping gathers early feedback from users, engineers and stakeholders. This lets you substantiate design choices and address problems before they propagate into tooling or production. Four reasons to make ideas tangible:
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Learn faster
A physical prototype shows how a design behaves in practice. Feedback from users, designers and engineers reveals whether the ergonomics are right, the interaction is intuitive and the product feels good to use. Targeted tests also help investigate safety questions. By implementing improvements early, you reduce the time and budget lost to incorrect assumptions.
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Reduce risks
A mistake we discover early can prevent costly corrections in tooling or production. We test multidisciplinary for manufacturability, assembly, material behaviour and durability. We also consider circularity questions: can the product be disassembled later and is a recyclable plastic suitable? This way we identify bottlenecks before investing in production moulds or production lines.
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Convince stakeholders
Investors, partners and end users understand a product better when they can experience it physically. A demonstrator supports discussions about funding, collaboration or a market test. Besides functionality we therefore pay attention to appearance. A prototype or small series shows what already works and what still needs validating.
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The bridge to production
With rapid tooling we make small series for practical tests. This lets us check assembly, tolerances and performance before investing in moulds for larger runs. This pre-production phase reveals remaining risks and can shorten the route to market. The connection with our Plastics Factory links first sketches and a few prototypes to small batches, market tests and preparation for larger series.
From first model to realistic testing
In the PEZY Protolab and the Plastics Factory, design, prototyping and production come together. A form study helps assess dimensions and ergonomics. A functional prototype or small series makes it possible to test material behaviour, assembly and performance as well. We match the technical approach to the question you want to answer.
Discuss your prototype
Incorporating circularity into your prototype
Sustainable development requires decisions in design, materials and across the whole chain. That is why we investigate circularity already at the prototype stage. Our e-book Design for Recycling – Design from Recycling shows how to design for recycling and from recycled materials. Request it for free and use the insights for your design choices.
Request the e-bookMethods and techniques for prototyping
The right technique starts with the question you want to answer.
In the PEZY Protolab we create the first tangible versions of a product, which can be quickly tested for shape, dimensions and ergonomics. Once the fundamentals are right, the work moves to our own Plastics Factory, equipped with 3D printers, a mould workshop, injection moulding machines and a range of testing and finishing tools.
We don’t limit ourselves to plastics. With metalworking tools and components such as metal inserts or upholstery, we build complete prototypes and small series that match the intended final result as closely as possible.
3D printing
Using SLA, SLS and FDM we quickly produce models for form and functional testing. Which printing technique is suitable depends on what needs to be assessed: for example dimensions, ergonomics or the functioning of a part.
CNC machining
We use CNC machining for strong and precise parts. This route is suitable when material choice and dimensional accuracy are important for a representative test.
Vacuum casting
With vacuum casting or urethane casting we produce small series with a high-quality surface finish. This allows multiple models to be used for evaluation, demonstration or user testing.
Rapid tooling
Rapid tooling is the creation of tools for prototypes and small series. With soft tooling and aluminium moulds we can injection mould parts in limited quantities. This lets us test assembly, tolerances and performance via a production route aligned with the intended final product, before investing in moulds for larger series.
Injection moulding with pilot tooling
Conventional injection moulding combined with pilot tooling produces representative final products for further validation. It links prototyping with pilot production and prepares the way for larger series.
A trade-off for each prototype
Each method has strengths and limitations in speed, material choice, tolerances and cost. Because design and production work closely together, we can switch between techniques. We select the approach that suits the project phase and the question the prototype must answer.
Philips OneUp
Discover how PEZY collaborated on the Philips OneUp: a floor cleaner that lets you mop without a bucket.
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Katrin Hand Towel XL Dispenser
A high-capacity dispenser developed with a thoughtful rib structure for reliable dispensing and easy maintenance.
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Braster
A medical product that brings user research, product design and technical development together.
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Victron Energy EV Charger
A charging station for electric cars, designed for the home market.
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Examples of our developed products
PEZY develops innovative products for a wide range of markets, from consumer goods to medical devices. See how our teams turn ideas into usable and manufacturable products.
View all our workWhy PEZY
Why choose prototyping at PEZY?
At PEZY the initial sketch, physical prototypes and tooling come together. Our multidisciplinary teams of designers, plastics engineers and production managers work closely together and switch quickly between disciplines. The direct link with the PEZY Plastics Factory helps us move from idea to models that we can test purposefully and prepares scaling up to mass production early on. We have experience across a wide range of sectors, from medical technology to consumer goods and industrial applications. We combine that knowledge in every project. We look beyond functionality: circular development is part of the process from the outset, with attention to manufacturability, scalability and the product’s lifespan.
3 locations
Design, engineering and production in close collaboration.
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.
Discuss your prototype with PEZY
Do you want to make an idea tangible, test a design or take the step to a small production run? Tell us what you want to learn and where you are now. Together we will determine which prototype and which technique suit that need.