When it comes to custom manufacturing, prototyping remains an integral part of the design process. Whether you are testing the fit, form, and functionality of a new product, evaluating the feasibility of a unique material, or merely experimenting with novel ideas and concepts, prototyping services enable us to venture into new territories. The prototyping services at GM Nameplate (GMN) not only provide quick-turn solutions but also offer design support to help customers navigate a path towards production.
The prototyping solutions offered by GMN can be briefly divided into the following three types -
1) Quick-turn prototypes
Quick-turn prototypes, also known as rapid concept prototypes, put the focus on speed. This program aims to deliver a product into the customer’s hands as quickly as possible, which in turn takes them a step closer to production. Customers can assess multiple design considerations with accelerated lead times and reduced costs compared to full production parts. While rapid concept prototypes are not intended for qualification testing, they facilitate customers to experiment, refine, evaluate, and validate designs while making swift iterations. So, if you are looking to assess different material options for a gasket or compare a satin finish versus a gloss finish, then rapid concept prototyping is the way to go!
GMN has a dedicated product development team and manufacturing equipment that operates outside of regular production schedules, which helps us stay agile and accommodate varied needs. While developing prototypes, GMN utilizes digital printing for parts that will often use alternate printing processes in final production to remain cost and time-efficient. Similarly, for die-cut prototypes, GMN often uses materials specified for the final product but utilizes laser cutting and other “soft tooling” methods before transitioning to hard tooling for production. This allows customers to compare multiple design options without investing in the appropriate production tooling.
2) Conceptual development prototypes
Conceptual development prototypes focus on translating concepts into concrete solutions. This development process optimizes ideas to achieve a viable product by evolving designs towards production-friendly solutions. By letting us perform quick risk mitigation testing on new materials or designs on the front-end, it reduces unexpected challenges later in the design process. While this prototyping solution often comes into play while working with unique materials, it can also be helpful if a design is ahead of the technology curve. When a customer approaches GMN with unique material, we can address the unknowns associated with processing the material. This includes testing ink adhesion, verifying substrate compatibility with the manufacturing processes, optimizing processing parameters, and testing new design applications before engaging in larger production runs.
GMN’s customers bring a variety of cutting-edge products to market and the complex nature of these projects requires a focused and methodical approach to development. Conceptual development prototypes are often accompanied by a formal development proposal including a statement of work with discrete milestones that allow GMN to periodically regroup with its customers to determine the design or processing solution that best meets their needs.
3) Pre-production development prototypes
Pre-production development prototypes bring a design concept to a repeatable and robust production solution. Pre-production prototyping ensures that regulatory requirements, including Design Failure Mode and Effect Analysis (DFMEA), Process Failure Mode Effects Analysis (PFMEA), or Production Part Approval Process (PPAP), are met. Pre-production development prototypes emphasize on establishing process capabilities, improving yields, and optimizing designs for high-volume manufacturing. Since this approach utilizes all of the standard full-scale production equipment and process controls, it is best suited for products that are ready to transition into volume production and can be used for purposes such as final qualification and testing.