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On this page (13 sections)
- Types of prototypes we build
- Quick-turn PCB prototypes
- Iterate with confidence
- What to test at each prototype stage
- Reducing the number of prototype rounds
- Budgeting for prototypes
- From prototype to production with one partner
- Prototyping for different industries
- What you receive
- Getting started
- Quick-turn fabrication options
- Prototype enclosures
- Feedback for production
Types of prototypes we build
Proof-of-concept builds demonstrate that the core idea works, often using development boards and modules. Engineering prototypes use custom PCBs close to the final design to test performance. Pre-production prototypes use final components, enclosures and processes to validate manufacturability. Pilot batches produce small quantities for field trials, certification and early customers.
Choosing the right prototype type for each stage saves time and money. Early prototypes can be rough but fast, while later prototypes should look and behave like the final product.
Quick-turn PCB prototypes
We fabricate prototype PCBs through trusted partners and assemble them in-house, which keeps turnaround short and gives our engineers direct access to the boards. Problems found during bring-up are corrected in the next revision immediately.
Having assembly and engineering in the same building means a problem found during bring-up can be discussed with the person who assembled the board, speeding up diagnosis and fixes.
Iterate with confidence
Each prototype round is documented: what changed, why, and what was tested. This record makes design decisions traceable and prevents fixed issues from returning. When the design is frozen, the same files and test procedures move into production.
A clear revision history also helps when talking to investors, customers or certification labs, as it shows a disciplined development process.
What to test at each prototype stage
Proof-of-concept prototypes answer one question: does the core idea work? Engineering prototypes test electrical performance, power consumption, interfaces and firmware. Pre-production prototypes check manufacturability, enclosure fit, assembly time and test coverage. Pilot builds validate the production process itself and provide units for certification and early customers.
Defining test goals for each stage keeps prototype rounds focused and avoids spending money on polish before the fundamentals are proven.
Reducing the number of prototype rounds
Every extra prototype round adds weeks and cost. Careful schematic review, verified footprints, DFM checks and simulation where appropriate catch many issues before fabrication. During bring-up, we test systematically and record every issue so that all fixes go into the next revision together.
Grouping fixes into a single revision avoids multiple small rounds. We also prioritise fixes so that critical issues are resolved first if schedule pressure is high.
Budgeting for prototypes
Prototype unit costs are higher than production because of setup, small quantities and quick-turn fabrication. Plan for at least two prototype rounds in a typical product, plus a pilot batch. We provide a cost estimate for each stage so you can plan funding.
Costs can be reduced by sharing panels, using standard materials and limiting quantities to what is needed for testing. We advise on these options for each round.
From prototype to production with one partner
Because we also manufacture, the files, BOM and test procedures used for prototypes move directly into production. There is no hand-off to a new manufacturer and no re-learning of the product.
This continuity shortens the path to market and reduces the risk of new problems appearing when production starts.
Prototyping for different industries
Industrial customers prototype new controllers and instruments, medical start-ups build early devices for evaluation, consumer brands test designs with users and IoT companies trial connected sensors in the field.
Each industry has different priorities for prototypes, such as appearance for consumer products or measurement accuracy for instruments. We tailor the prototype plan accordingly.
What you receive
Working prototype units, notes from bring-up and testing, a list of recommended changes and updated design files for the next revision.
You also receive our observations on manufacturability and cost, which help you plan the next stage and budget for production.
Getting started
Tell us what the prototype needs to demonstrate and when you need it. We will propose the approach and quote.
Even if requirements are still evolving, we can start with a proof of concept to test key assumptions and refine the specification as you learn.
Quick-turn fabrication options
Prototype PCBs can be ordered with faster turnaround when schedules are tight. We advise on the trade-off between speed and cost for each round.
For less urgent rounds, standard turnaround reduces cost. We plan each round with you to balance schedule and budget.
Prototype enclosures
Early enclosures can use off-the-shelf boxes, modified standard enclosures or 3D-printed parts before investing in tooling.
Using standard enclosures early lets you test fit and user experience before committing to custom tooling.
Feedback for production
Every prototype round produces notes on manufacturability, assembly time and test coverage that improve the production design.
These notes become part of the design record and guide decisions about panelisation, test strategy and assembly sequence.
