Validating Design, Engineering, and Manufacturability. Brightstar Precision at Work
Rapid prototyping to manufacturing
Engineering Prototype
What is an Engineering Prototype
An engineering prototype is a critical step in the product development process to verify the manufacturability and functionality of a design.
Engineering prototypes are a series of components manufactured during the product design and engineering validation phases, combining engineering and design to represent the final product. These prototypes are typically produced using rapid prototyping techniques, such as CNC machining and 3D printing, to undergo rigorous testing and evaluation of product design, engineering feasibility, and manufacturability. The manufacture and testing of engineering prototypes are crucial to ensure that the design meets the expected product specifications and performance, and help identify issues and areas for improvement before committing to expensive production tools and processes.
Why conduct engineering prototype validation and testing?
We perform engineering prototype validation and testing to:
1. Verify Design and Functionality: Ensure the prototype meets specifications and works as intended.
2. Assess Engineering Feasibility: Confirm the design is practical and can be manufactured reliably.
3. Identify Issues Early: Detect problems and make improvements before investing in costly production tools.
4. Optimize Manufacturing Processes: Validate that the design can be efficiently produced at scale.
5. Meet Certification Standards: Ensure compliance with relevant industry standards and regulations.
Engineering prototype verification process
Concept design
Clear demand analysis, conceptual design, and converting concepts into specific design drawings and specifications
Manufacturing analysis
Brightstar Engineers conduct a DFM (Design for Manufacturability) analysis on the customer's CAD drawings and provide report.
Prototyping
Use prototype CNC machining and 3D rapid prototyping to create engineering prototypes that are close to the final product, which will be tested and evaluated to ensure the product's functionality, engineering, performance, and safety.
Why cooperate with Brightstar?
One-Stop Service: We offer one-stop services from IQC to surface finishing and shipping, leveraging in-house high-precision tech like CNC, 3D printing, and injection molding, and partner with stable suppliers.
Quick Response & Short Turnaround: Brightstar adapts quickly to design changes and urgent needs, shortening the product development cycle.
Expertise in Prototype Manufacturing: Our professional engineering and manufacturing team, skilled in various manufacturing processes, provides comprehensive and custom prototype services.
Pre-Production CAD Review and DFM Analysis: We assist with CAD reviews and DFM analysis to ensure manufacturability.
Material and Process Optimization: We optimize materials and processes, find potential issues, and offer cost-effective design recommendations.
Quality Control: Quality control runs throughout our whole prototype manufacturing process, covering IQC, IPQC, FAI, and FQC.
Brightstar Engineering Prototyping Cases
Car
Medical
Electronic
3 Stages of Engineering Validation, their Differences and Connections
Engineering verification is a progressive and rigorous process that integrates design and engineering development, as well as prototype manufacturing, to ensure that the product meets the established design requirements, performance standards and specifications. This process is designed to ensure that the product can smoothly enter the mass production stage through a series of objective and comprehensive tests. The following are several key stages of engineering verification:
Engineering Verification Test (EVT)
EVT is a series of basic performance tests including power, thermal and EMI to verify that the product meets the functional requirements of the design specification. EVT versions are derived from CNC machining, vacuum casting or rapid prototyping.
┅ Quantity range is 20-50 pieces
┅ Material and mechanical properties of the parts must meet the test requirements
┅ Tighter tolerances are required to verify assembly and use functions
┅ Basic performance tests including power, thermal and EMI
┅ Identify design or process defects
┅ Identify design or process improvement options
┅ Perform a second EVT after changes are made
Design Verification Test (DVT)
DVT is an intensive series of test procedures to verify that the product meets specifications, industry standards and certifications.
┅ Quantity is usually between 50 and 200 pieces.
┅ All parts should come from molds or pre-production processes.
┅ Ensure that the production process meets chemical and environmental requirements.
┅ Extensive reliability and compliance testing, including flame retardancy, drop, waterproof, battery safety, etc.
┅ Verify product certifications and standards in different countries or regions, such as RoHS, CE, FCC, UL, etc.
┅ Failure analysis and corrective actions need to be carried out quickly.
┅ Optimize production schedules.
Production Verification Test (PVT)
PVT is the pilot production phase of the product development process, designed to identify and evaluate defects and optimization effects at each stage of the production line by testing the entire production line to ensure quality assurance.
┅ Product quantity is usually more than 500 pieces, which is very suitable for sale.
┅ Tools can be used without changes.
┅ Production verification (yield, time, target cost, rework time, etc.)
┅ Design for Assembly (DFA) verification to optimize the assembly process and reduce time and cost.
┅ Development and testing of Quality Assurance (QA) and Quality Control (QC) procedures.
┅ Standard Operating Procedure (SOP) development and employee training procedures.
Customer Testimonials
What is the product development process?
The product development process usually includes stages such as concept verification, appearance model, engineering prototype (manufacturing design supports DFM verification), pilot production and mature production.
What is the difference between an engineering prototype and a final product?
An engineering prototype is mainly used to test the feasibility, functionality and performance of a design during the development stage. It may not be as perfect as the final product in appearance and refinement, and may not contain all the functions of the final product. Prototypes are manufactured in limited quantities and are usually only used for testing and verification, while the final product is for mass production and market sales. The engineering prototype is an intermediate step in the product improvement process, while the final product is a finished product that has been carefully designed and tested and is ready to be launched on the market.
How to ensure the manufacturability of engineering prototypes?
The key is to incorporate manufacturability principles into the early design stage, select materials and processes, carefully plan the manufacturing process, and use appropriate technologies to manufacture prototypes. Cooperate with professional manufacturers to prevent manufacturing problems using simulation software, provide DFM analysis, strict quality control and comprehensive testing to verify prototype performance, accurately implement engineering prototypes, improve production efficiency and reduce costs.
What is the time and cost of engineered prototypes development?
The time and cost of engineered prototypes dev depends on the type, complexity and stage of the product. It may take from six months to several years from the concept stage to commercial production, and the cost varies according to the complexity of the prototype and the product.