Build guide
How to get a prototype manufactured.
Prototype manufacturing is the path from a finished design to a part you can hold. It is not one step, it is a sequence of decisions about process, factory and scope, each of which decides what the next one costs. This is how we run it.
Why it matters
The quote is not the cost.
A prototype quote is a snapshot of one design at one moment. Every revision after the quote moves the number, and most revisions happen because the design was not settled before the quote was asked for. Settling the design first turns the quote from a guess into a decision.
A factory is not a process.
Choosing a factory before choosing a process puts the question in the wrong order. A factory that cannot run the process you need will quote for a substitute, and the substitute will not answer your question. Match the process to the question, then find a factory that runs it.
The stages
Five stages from design file to first article
Each stage answers one question and gates the next. Skipping a stage does not save time, it moves the cost of the skipped question into the next build, where it is more expensive.
- 01
Prepare the design package
BEFORE YOU ASK ANYONE FOR A QUOTE
A manufacturer cannot quote what it cannot see. The package is a 3D model in a transferable format, 2D drawings with the dimensions and tolerances that matter, a bill of materials with named parts, and a short brief on what the prototype is for. A vague request gets a vague quote, and a vague quote is where budgets start to drift. The audit exists partly to produce this package.
- 02
Choose the prototype process
MATCH THE PROCESS TO THE QUESTION
3D printing answers geometry and fit questions cheaply. CNC machining answers material and tolerance questions. Urethane casting answers appearance and small batch questions. Injection moulding answers production questions, but it is expensive to start. The mistake is choosing a process for convenience and discovering it cannot transfer to production. Match the process to the question the prototype answers.
- 03
Find and vet a manufacturer
CAPABILITY MATTERS MORE THAN PRICE
A factory that quotes low and cannot hit your tolerance is more expensive than one that quotes honestly. The questions are whether the factory runs the process you need, whether it has done similar work, whether it can show you a quality record, and whether its business identity is verifiable. This is the gap the verification framework exists to close, because a cheap quote from an unverifiable shop is not a saving, it is a risk.
- 04
Quote and scope the build
FIX THE SCOPE BEFORE THE SPEND
A prototype quote should separate one time costs, tooling, setup and fixtures, from per part costs. It should state the process, the material, the finish, the lead time and the inspection scope. A quote that bundles everything into one number hides where the money goes and where the risk sits. Scope the build, agree the deliverables, and hold the scope fixed while the build runs.
- 05
Build and inspect the first article
THE PART THAT PROVES THE PROCESS
The first article is the first part made on the intended process, inspected against the drawing. It answers whether the process, the tooling and the setup produce a part that meets specification. A prototype that passes on the bench but fails first article inspection means the process is not settled, and production will inherit the same failure. The first article is the gate between prototype and production.
Choosing a process
Four prototype processes, and what each answers
The process decides what question the prototype can answer. A printed part answers fit. A machined part answers material. A cast part answers appearance. A moulded part answers production. Picking the right one keeps the prototype work transferable to the build that follows.
3D printing
FDM, SLA and SLS each suit a different question. FDM is the cheapest way to check fit and form. SLA gives a smooth, accurate surface for appearance models. SLS produces functional nylon parts without support geometry. All three tolerate features that moulding will not, so a printed prototype is a starting point, not a production proof.
CNC machining
Subtractive machining in metal or plastic produces parts close to production material and tolerance. It is slower and more expensive per part than printing, and it does not represent the moulding process, but it answers whether the geometry works in the real material. Use it when a printed part would not tell you what you need to know.
Urethane casting
Silicone moulds cast from a master pattern produce small batches of polyurethane parts that look and feel close to moulded production. It suits appearance models, user testing and short runs of 10 to 100 parts without tooling investment. The material is not the production grade, so it answers form and feel, not long term performance.
Injection moulding
Steel or aluminium tooling produces parts on the real production process. It is the only way to prove the part, the material and the process together, and it is where unit price is decided. Tooling is a one time investment, so it belongs after the design is settled, not before. A soft tool validates geometry cheaply, a steel tool commits to it.
Common mistakes
Three patterns that derail a prototype build
Quoting before the design is settled.
A quote against an unfinished design is a number that will move. Every revision after the quote changes the tooling, the process or the bill of materials, and the number follows. Settle the design, then quote, and the quote is a decision, not a guess.
Choosing the cheapest factory.
The cheapest quote usually means the thinnest margin for quality, the least inspection, and the weakest traceability. The cost of a failed prototype batch, a rework cycle or a missed deadline is higher than the saving on the quote. Capability and verification beat price on a first build.
Treating the prototype as the product.
A prototype proves a question. It is not the production part, and it does not prove the production process unless it was built on it. Confusing the two leads founders to commit to production on evidence the prototype cannot provide. Keep the prototype question explicit, and separate it from the production decision.
FAQ
What founders ask about prototype manufacturing
How do I get a prototype manufactured?
Start with a complete design package, a 3D model, 2D drawings with tolerances, a bill of materials and a short brief. Match the prototype process to the question you are answering, whether that is fit, function, appearance or production. Then find a manufacturer that runs that process and can show you similar work, scope the build with a quote that separates one time and per part costs, and inspect the first article against your drawing. The audit produces the design package and the process recommendation before you spend on the build.
How do I find a manufacturer to make a prototype?
Look for a factory that runs the process you need, has done similar work, and can show a verifiable business identity and a quality record. A quote is not evidence of capability. The risk with an unverifiable shop is not just price drift, it is that the parts may not meet specification and the factory may not be accountable. This is why we verify every factory against a published five check framework before it touches a project.
What is the difference between a prototype and a production part?
A prototype answers a specific question, like fit, function, appearance or process proof, and it is built on whatever process suits that question. A production part is built on the intended manufacturing process, at volume, to specification, with inspection and traceability. A 3D printed prototype can prove geometry but says nothing about whether the part moulds well. Only a first article on the production process proves the production part.
How long does it take to manufacture a prototype?
A printed part takes days. A CNC machined part takes one to two weeks. A urethane cast batch takes two to three weeks once the master is ready. An injection moulded first article takes four to ten weeks, depending on tooling complexity and whether the tool is aluminium or steel. The schedule is set by the process and the question, which is why matching them up front keeps the timeline honest.
Is rapid prototyping the same as prototype manufacturing?
Rapid prototyping usually means 3D printing and other quick, low setup processes. It is fast and cheap per part, and it answers fit, form and concept questions well. It does not answer production questions, because the process, the material and the tolerances are not the production ones. Prototype manufacturing is the broader term that includes rapid prototyping and the slower, production intent processes that prove the part can be built at volume.
How much does it cost to manufacture a prototype?
It depends on the process and the question. A 3D printed part costs tens to low hundreds of euros. A CNC machined part costs hundreds to low thousands. A urethane cast batch of 20 parts costs a few thousand. An injection moulded first article, with tooling, costs from roughly EUR 8,000 for a soft tool to EUR 40,000 or more for a steel mould. The stage by stage breakdown is in our cost of prototyping guide.
Can I use the same factory for prototyping and production?
Often yes, and it is usually better, because the factory learns your product during prototyping and carries that into production. The condition is that the factory runs both the prototype process and the production process, or works with a partner that does. A factory that only prints cannot produce your moulded parts. Matching the factory to both the prototype and the production process keeps the work transferable.
What should I send a manufacturer to get a prototype quote?
Send a 3D model in STEP or IGES, 2D drawings with the dimensions and tolerances that matter, a bill of materials for any assembled part, the intended material grade, the finish, the quantity, and a one line brief on what the prototype is for. The brief matters because it tells the factory which process suits the question, and a factory that understands the question quotes more honestly than one guessing at it.
A guide shows the path. An audit walks it with you.
The Production Readiness Audit puts an engineer on your actual files and returns a written report with the process recommendation, the cost drivers, the required changes and a clear verdict. If the answer is no, you get the changes that turn it into a yes.
Get your design reviewed