Physical Prototypes for Development
What Physical Prototypes Help Designers Test
| Factor | Purpose of Testing | Example |
|---|---|---|
| Scale | Assess whether the size and proportions are appropriate | Holding a model smartphone to test thumb reach |
| Aesthetics | Explore surface finish, shape, and colour appeal | Reviewing car dashboard texture and trim colour |
| Materials | Trial structural integrity, flexibility, texture, or sustainability | Testing 3D-printed casing vs. injection moulded ABS |
| Function | Check how the product operates or performs tasks | Building a prototype door handle to test the mechanism |
| Performance | Evaluate durability, wear, comfort, or real-world reliability | Using a prototype running shoe for test wear over 2 weeks |
- Physical prototypes are not just about testing functionality.
- They also help designers understand how a product will be perceived and used in the real world.
Types of Physical Prototypes
Mock Up
Mock-up
A rough or basic model, often made from inexpensive materials, used to explore form or function quickly.
- Typically used for testing size, proportions, ergonomics, and basic layout.
- Quick to build using cheap or recycled materials (e.g. cardboard, foam)
- Prioritises speed over accuracy
- Encourages early feedback and iteration
- May be full-scale or rough approximation
Scale Model
Scale Model
A proportionally scaled-down (or up) version of the product, often non-functional.
- Typically used to test proportions, spatial relationships, and overall design.
- Maintains proportions, but not size.
- Often used when full-size models are impractical (e.g. architecture, vehicle design).
- Can help stakeholders visualise spatial layout.
- May be static or partially interactive.
Aesthetic Model
Aesthetic Model
A high-fidelity, non-functional model used to represent the final appearance.
- Typically used for evaluating colour, finish, form, and brand appeal.
- High visual detail but non-functional.
- Used in presentations, stakeholder approval, or branding review.
- Materials chosen to replicate final look and feel.
- Typically built in later stages of development
Instrumented Model
Instrumented Models
A functional prototype fitted with sensors or measurement tools to collect data.
- Typically used to measure performance, e.g. stress, temperature, movement.
- Includes sensors or monitoring tools.
- Provides quantitative data (e.g. force, speed, temperature).
- Used in performance testing or to validate simulation results.
- Can be expensive or require technical integration
Physical prototypes are often created in multiple stages, increasing in fidelity, to refine the product based on real-world testing and feedback.
- Think of a physical prototype as a dress rehearsal for a play.
- It allows the team to see how everything comes together, identify any issues, and make adjustments before the final performance.
The Limitations of Physical Prototypes
- Cost and Time
- Building physical prototypes can be expensive and time-consuming, especially for complex designs.
- Limited Scope
- A single prototype may not capture all aspects of a design, requiring multiple iterations.
- Material Constraints
- Prototypes may use different materials than the final product, affecting accuracy in testing.
- Assuming that a single prototype can address all design issues.
- In reality, multiple prototypes are often needed to test different aspects of a product.
Explain why prototypes would be used in the testing and evaluation of a new insulated travel mug. [3]
Solution
Award [1] for each of three distinct points, up to [3] total. For example:
- Thermal performance testing: Prototypes allow measurement of how long the mug keeps drinks hot or cold under real conditions. ✓
- Leak and seal evaluation: Early models can be filled, shaken, or tipped to check that the lid and seals prevent spills. ✓
- Ergonomic feedback: User trials reveal issues with handle shape, grip comfort, or lid operation that guide refinements. ✓
(Any equivalent reasons for using prototypes in testing and evaluation of the travel mug.)
