Lessons in prototyping: Figuring out the best type of prototype

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When approaching prototype creation, you have options. This expert weighs in with her guidance. Photo courtesy

As you continue your journey of developing and bringing a new product to the market, you have a series of decisions to make when it comes to prototyping — whether you're going to launch a hardware or a software product, or the combination of both — you need to have a prototype made.

Before you begin, there are a number of things to consider. In an article for InnovationMap last week, I looked at major choice points and their implications that will help you navigate the process in the most efficient way.

After you successfully laid the foundation for the development process and got you CAD models ready, you arrive at the next choice. Prior to making a prototype of your invention you need to decide what type of prototype you're going to build. Whether you're making it yourself or hiring a rapid prototyping company, you need to know the purpose your prototype will fulfil because it will help to select proper methods, techniques, and materials for building. With that in mind, let's go through the types of prototypes and purposes behind building them.

Types of Prototypes

Mockup

This type is usually used as a simple representation of your product idea, to gauge physical dimensions and see its rough look. It's especially useful for making physical models of complex and large products without investing a significant amount from the start. Mockup is perfect for initial market research and various types of early testing.

Proof of concept

This type of prototype is built when you need to validate your idea and prove that it can be realized. It comes in handy when approaching potential partners and investors.

Functional prototype

This kind of prototype is also called a "looks- and works-like" model because it has both technical and visual features of the product presented. It is used for testing product's functionality, conducting consumer surveys, and fundraising campaigns.

Pre-production prototype

This is the most complex type that is made at the latest stage of product development. It's used for ergonomics, manufacturability, and material testing, as well as to minimize risks of defects during manufacturing. This is a model that manufacturers use to produce the final product.

Choosing to Partner with Prototyping Company

It's important to note that prototyping is an iterative process. It is a fusion of art and science that helps you to uncover the full potential of your product, which in turn increases its chances for market success. Therefore, you will likely go through several types of prototypes, with each kind usually requiring a few versions to achieve the parameters you set for the model.

And this process also requires help of a company that builds prototypes or of a professional product development team. You can start looking for the one after you made your first mockup or proof of concept. It is recommended because creating more complex prototypes implies the use of sophisticated equipment, sourcing of materials and components that could be too expensive or complicated to do without an established network of suppliers. Plus, skills and experience play a huge role in creating quality prototypes. Taking all three factors – equipment, experience and skills - into account, it's smart to outsource your prototyping needs to a professional company.

This article is a follow up article to my post from last week. I have also previously contributed to guest columns on the following:

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Onega Ulanova is the founder of OKGlobal.

When approaching prototype creation, you must make a series of decisions. This expert weighs in with her expertise. Photo courtesy

Lessons in prototyping: Choosing the right approach to product development

guest column

When embarking on the journey of developing and bringing a new product to the market, you as an inventor have to consider a multitude of aspects that add to the overall market success of your final product. And prototyping is one of the key product development stages that helps you achieve that.

Whether you're going to launch a hardware or a software product, or the combination of both — you need to have a prototype made. First, it allows you to validate your idea and see if it's worth investing time and money into. Second, it creates opportunities for product improvement, detection and elimination of design flaws, and cost reduction, especially during manufacturing.

Therefore, you will need to make a set of choices before you actually build a prototype to ensure that it results in a viable, cost-effective, and quality market-ready product. Let's look at major choice points and their implications that will help you navigate the process in the most efficient way.

To begin, let's look at the various options you have.

The success of any process lies in its foundation. Hence, before anything else you need to decide on the product development approach you're going to follow. Some inexperienced inventors, for instance, choose to go from product idea straight to having a prototype made. They skip three initial steps that are crucial for building a sound road map of the development process and creating a product with a maximum market potential.

In most cases, those inventors end up coming to companies that build prototypes to start from scratch. Usually, it's because they hit a dead end with their prototype or a product was manufactured with many defects. The latter is always a result of improperly optimized pre-production prototype, if optimized at all.

The extensive experience of our product development team shows that a methodological approach to the entire process, prototyping in particular, yields the most effective results. That's why we always recommend it to those inventors who choose to DIY their prototype. If you're one of them, here is a short version of the approach with steps it implies that you can use prior to prototyping. You can find the in-depth version here.

1. Product discovery

To set the path for the development of your idea you need to identify your product's strengths, weaknesses, opportunities, and threats. In other words, you need to conduct a SWOT analysis, which will help you learn about:

  • intellectual property opportunities
  • your competition and target market
  • features your product should have
  • time and cost of your idea development.

2. Concept design

Based on the results of the SWOT analysis, you can establish the road map of the development of your product and get to creating a concept or industrial design. Concept design is a virtual representation of your idea translated into 2D renderings and 3D CAD models that show you a rough look and functions your product will have. These should be built in accordance with preferences of your target audience to ensure the product's market fit. Concept design is usually made by a professional Industrial Designer. But if you have a basic knowledge of how to use industrial design software applications, then you can make it yourself.

3. Market and prior art research 

Another important step before prototyping is gathering and analyzing feedback from potential consumers. This is done through market research. With a concept design developed, you can conduct focus groups and consumer surveys to understand if the audience likes your idea. The information you get will give you more opportunities to improve your idea and add necessary changes to the design before prototyping, thus reducing the cost of the process and increasing market potential.

Prior Art Search, or research of existing patents, provides some of the benefits as market research. But its main purpose is to identify similar product ideas that have already been patented, so that you can make your product stand out by adding unique features to the design, as well as avoid a conflict of patent rights.

In a follow up article next week, we will discuss more decisions you must make during the prototype process. I have also previously contributed to guest columns on the following:

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Onega Ulanova is the founder of OKGlobal.

The journey from ideation to creation, and then manufacturing can be difficult, but rewarding. Photo courtesy of OKGlobal

These are the risks and rewards of prototyping, according to Houston expert

Guest column

We live in a digital world. Music, movies, and even family photos have become primarily digital. Computer software offers us a range of comfort and efficiency and has become part of our daily routine. So, why would anyone want to build a career around physical product development?

Simple, almost every software product or next big thing relies on a well-executed physical product development project. Apps need a place to run, games need a console to be played, and pictures need a camera to be taken.

Physical product development means dreaming of something that does not yet exist and solves an existing problem. It means taking an intangible idea and making it into a physical item that people can see, touch, and use.

The journey from ideation to creation, and then manufacturing can be difficult, but rewarding. By understanding the process, you'll find that not only is your inspiration worth pursuing, but it may be one of the most fulfilling things you will ever do.

From inspiration to perspiration

Every product development project begins with a vision, the identification of a problem and a solution for that problem. That initial spark of inspiration is what drives the entire project.

Look for a problem that hasn't been solved and solve that problem, or try the reverse. Think of a product idea, and then work backwards to find the need. Regardless, one cannot be successful without the other.

Projects require this problem, or need, because it embodies the product's target market. A product idea without a well-defined need has no reason to exist, and if it did, it would be downright perplexing.

Once you identify your need and idea, start your research.

Test the validity of your idea. How much of a market exists for your problem-solving miracle? Send out surveys, look at various markets, conduct data analyses, and generally, do everything in your power to ensure that your product should be made.

Then, start making something.

From concept to reality

The design, prototype and manufacturing stages are what bring your inspiration closer to reality. Turning it into a concrete product means letting go, and that can be scary.

Initial concept designs can be done in a variety of different ways. Detailed sketches and blueprints could be drawn up, or CAD drawings can be created. This concept design can help you explain your idea to others, including partners and investors. What works even better, though, are prototypes.

A prototype is a preliminary model of your product that can help you determine the feasibility of different aspects of your design. You can make a functional prototype, which acts as a proof-of-concept for your idea, or you may create aesthetic prototypes that will test the look and feel of your product.

Once you nail down the ideal appearance and physicality of your product, you will need to combine the two disciplines as seamlessly as possible. This performance prototype will effectively demo your final product.

Finally, you can prepare your product for production. Designing for manufacturability (DFM) means ensuring that your product can be made efficiently and cost-effectively. DFM allows you to mistake-proof your product by choosing the best manufacturing materials and methods, while keeping in mind the appropriate regulations for your desired market.

From nothing into something

The product development process often changes. Trends like crowdsourcing and innovative fast-to-market solutions constantly upend the process and make it new again. Some automakers, for example, want to innovate the design process using existing customer data — similar to how companies like Microsoft and Apple create iterative versions of their software product development projects.

Getting your product to market can be tough, but certain approaches can ease the burden. Create a simpler product. Fail fast and fail cheap with lean development, meaning limit your risk to maximize your return. Also, never underestimate the importance of customer feedback and intellectual property protection throughout the process.

With that said, invest in yourself and your inspiration, and you will avoid that nagging what if-mentality that drives regret. Great reward always requires risk, but there are also ways to invest smarter. Use available resources and give your dream the best chance for success.

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Onega Ulanova is the founder of OKGlobal.

Making a product that is worth further investing in, one that customers will want to buy, requires several prototypes, sometimes tens of prototypes to prove the concept and perfect your idea. Photo courtesy of OKGlobal

Houston expert shares why prototyping is so important to startups

guest column

Rarely in life is anything perfect on the first attempt. Writers write drafts that are proofed and edited. Musicians practice over and over, and athletes train for years to perfect their skills before becoming pros. So, it only makes sense that a product developer would develop a prototype before manufacturing their products.

But why? Why can't a perfectly designed product go straight from CAD to production? In reality, making a product that is worth further investing in, one that customers will want to buy, requires several prototypes, sometimes tens of prototypes to prove the concept and perfect your idea. Success comes through practice, just like with the musicians and the athletes.

Defining "prototype"

The word prototype derives from the Greek word meaning, "primitive form." It's an early sample or model of a product built to test a concept or process. Understanding that a prototype, by definition, is an early form of your final product, know that there is often a compromise between your prototype and the final product design. Differences in materials, manufacturing processes and design may create a slightly different look and feel of your prototype.

A full design build is expensive, and it can be time-consuming, so before manufacturing, we create a prototype. This allows you to look for any flaws and problems, figure out solutions, then rebuild with the updates. The process may repeat multiple times. Rapid prototyping is often used for your initial prototype, allowing you to inexpensively build and test the parts of the design that are most likely to be flawed, solving issues on the front end, before you make the full product.

This necessary step is needed to progress with your product development and take you further toward the commercialization and marketing of your product.

Why prototype?

Prototyping allows you to learn about the product, the design, and the functionality. By doing repetitive prototyping, you eliminate the guesswork and base your decisions on actual data and facts. Don't ever guess. Just learn. Just prototype.

Market Testing
It allows you to put a product in front of your consumers, get their opinion, and make changes based on how the consumer uses the prototype.

Save Money
You get to save money on initial product testing, by letting consumers test the product the way they would use it in real life.

Make Improvements
Prototyping gives you the opportunity to make improvements before putting your product into the market. You can see where/if your idea is flawed and flush it out before you manufacture products that won't sell.

Sales Forecasting
This is a difficult enough task as it is, but when you have a new product, it's hard to predict how it will fare against other products in the market. By watching how consumers use the prototype, and by seeing it work against other products, you will begin to understand the sales cycle for that product, allowing you to start your forecasting.

Product designers cannot predict how a consumer will react to a new product, so they release several prototypes, and gather feedback, switching up the products until they find what works for the consumer. When the product went to manufacturing, and finally to market, it was almost guaranteed to be a success—an unintended use for prototyping, and yet one of its best uses.

Designers realize that what looks good on paper isn't always what the end-user is going to want. By getting an inexpensive prototype in front of consumers, designers have been able to get quick feedback, adjust the product, and create a winning product.

When it doubt, prototype it out

The beauty of prototyping is that each prototype interaction opens new opportunities to improve your product. In all reality, you will need more than one prototype to develop a truly valuable product. Product development can get bogged down in meetings, where the product is analyzed, and guesses are made as to "the best way," but by getting to the rapid prototype stage, you can skip some of that guesswork and replace it with real information from the customers.


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Onega Ulanova is the founder of OKGlobal.

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10+ can't-miss Houston business and innovation events for October

where to be

Editor's note: Healthcare and energy conferences headline this month's slate of innovation events in Houston. But there's also time for family-friendly gatherings and pickleball socials. Here’s what not to miss in October and how to register. Please note: this article may be updated to add more events.

Oct. 2 — Joy in Medicine Initiative Symposium

The Houston Methodist Joy in Medicine Initiative Symposium will explore the power of connection in enhancing professional fulfillment for clinicians and healthcare teams, this year with the theme of "Forging New Paths: Leadership, Connection & Innovation to Sustain Joy in Medicine." Hear from Dr. Shlomit Schall, Houston Methodist Physician Organization president and CEO and chief physician executive; Houston Methodist CEO Marc Boom; and Dr. Albert Wu, from Johns Hopkins, author of Therefore, Let us Rejoice: Sustaining Joy in Medicine. Stick around for a networking happy hour.

This event is Friday, Oct. 2, from 8:30 a.m.-4:30 p.m. at Thompson Houston on Allen Parkway. Find more information here.

Oct. 6-7 — Hydrogen Americas Summit and Exhibition

Hydrogen Americas delivers an unparalleled opportunity to explore how hydrogen integrates with CCUS and other energy solutions under the new U.S. and Americas energy paradigm. This event moves to Houston in 2026, providing unmatched access to industry leaders and opportunities. The summit will include CCUS-dedicated sessions integrated directly into the conference programming, providing deeper insights into carbon capture, utilization and storage. Look forward to networking opportunities to connect with global suppliers, regional developers and key policymakers.

This event begins Oct. 6 at George R. Brown Convention Center. Register here.

Oct. 6-7 — Annual Energy Summit — Energy, Risk, and Geopolitics

The 10th annual energy summit is co-hosted by Baker Botts and the Center for Energy Studies at Rice University's Baker Institute. This year's summit, “Energy, Risk, and Geopolitics,” will explore how a changing geopolitical landscape and shifts in supply chain risks are impacting investment, innovation and market dynamics. The two-day program will include discussions spanning petroleum and LNG markets, critical minerals, electricity reliability, AI and power demand.

This event begins Oct. 6 at 7:30 am at James A Baker III Hall. The event will also be livestreamed. Register here.

Oct. 7 – Rockets Get You to Orbit. Culture Gets You to Stay

The Ion will host a morning discussion exploring humanity’s future in space. The event will feature Rick Tumlinson, author of Why Space? The Purpose of People; Scott Solomon, author of Becoming Martian; and David Alexander and Alexander Regier of Rice University’s new Space Humanities Initiative. The conversations will be moderated by EarthLight Foundation Director Junaid Mian.

This event is Wednesday, Oct. 7, from 8:30-11 a.m. at the Ion. Register here.

Oct. 8 — Greentown Labs’ Fall Pickleball Social

Greentown Labs hosts its fall social at Pickle Lab HTX this month. Enjoy friendly matches, networking and light bites. All skill sets are welcome.

This event is Thursday, Oct. 8, from 5:30-7:30 p.m. at Pickle Lab HTX. Register here.

Oct. 10 – Ion Family Tech Festival

Bring the whole family out to the second Ion Family Tech Festival. Kids will get to participate in hands-on STEAM workshops and learn more about STEAM-related careers.

This event is Saturday, Oct. 10, from 9 a.m.-12 p.m. at the Ion. Register here.

Oct. 13 – Mercury Fund Day at the Ion

Don’t miss the latest installment of Mercury Fund Day at the Ion, previously known as Software Day. The recurring monthly event features office hours (by application), a keynote and networking opportunities.

This event is Tuesday, Oct. 13, from 3:30-7 p.m. at the Ion. Register here.

Oct. 14 — Future of Global Energy Conference

This October, the sixth annual Future of Global Energy Conference kicks off, convening influential leaders from across energy, technology, finance and public policy who will come together to explore the forces defining the next era of global energy and Houston’s role in shaping it. Ryan Lance, Executive Chairman of ConocoPhillips and 2027 Chair of the Greater Houston Partnership’s Board of Directors, is the keynote speaker for this year’s conference, bringing a global perspective on rising demand, market volatility and Houston’s role in the next era of energy growth.

This event takes place Oct. 14 at the Marriott Marquis. Register here.

Oct. 17 — Energy Day 2026

Energy Day Houston is the nation’s largest free, family-friendly STEM festival. It features over 50 interactive exhibits and live demonstrations focused on traditional and emerging energy career paths to power up your curiosity.

This event begins at 11 a.m. on Oct. 17 at Sam Houston Park. Get details here.

Oct. 22 — Rice360 Innovation for Healthcare Access Conference

Researchers and innovators from Rice University, the Texas Medical Center, non-profit organizations, healthcare providers and others will come together to explore gaps in healthcare at the Innovation for Healthcare Access Conference. The event will feature speakers, workshops and case study presentations and will focus on innovations for the health of women and children in underserved rural and urban communities across Texas.

This event is Thursday, Oct. 22, from 8 a.m.-5 p.m. at the Rice University BioScience Research Collaborative (BRC). Register here.

Oct. 28-29 – TiECon 2026

TiE Houston, TiE Dallas and TiE Austin are joining forces to host TiEcon Texas 2026 at the Ion this month. The event will focus on how automation, artificial intelligence and emerging technologies are reshaping Texas industries, the economy and daily life. The conference will feature keynotes, panels, fireside chats and the TiE Hatch Pitch Competition.

This event starts Thursday, Oct. 29, at the Ion. Register here.

UH secures $5M in philanthropic gifts to bolster engineering, nursing

major gifts

The University of Houston has received two significant philanthropic gifts to advance innovation and healthcare, the college announced this month.

Manmohan Singh Kalsi and Marie-Luise Schubert Kalsi granted $4 million to UH’s Cullen College of Engineering to support endowed and current funds for graduate fellowships and industry interest in the mechanical and aerospace fields.

The gift is the Department of Mechanical and Aerospace Engineering’s largest donation in years, according to UH, and will establish two endowed professorships to attract and retain leading faculty. It will also create the Kalsi Faculty Research Fund, which aims to take emerging research to the next level.

Additionally, UH says it will also bring industry experts to campus to present and collaborate with students via the forthcoming Kalsi Seminar Series.

Manmohan Kalsi earned both his master’s degree and Ph.D. in mechanical engineering from UH. He went on to found Sugar Land-based Kalsi Engineering in 1978, which pioneered hydrodynamic rotary sealing technology and valve technology for nuclear power plants. In 2014, he established an endowed professorship within Cullen College in honor of the late UH professor Gabriel Fazekas.

"This gift provides a tremendous boost to our department's strategic momentum,” Karolos Grigoriadis, chair of the Department of Mechanical and Aerospace Engineering, said in a news release. “By simultaneously supporting faculty, graduate researchers and collaborative seminars, the Kalsis are strengthening every part of our research enterprise and creating new opportunities for discovery, collaboration and student mentorship.”

Meanwhile, Houston’s The Hamill Foundation also gave a $1 million gift to UH’s Andy and Barbara Gessner College of Nursing. The funds will establish The Hamill Foundation Endowed Professorship in Community Care Nursing, to support a faculty member focused on community-based nursing education, partnerships, research, and outreach to underserved communities in Houston.

Additionally, the funding will go toward efforts to address nurse shortages through the newly established UH Health program. The Hamill Foundation has donated $6 million previously to UH through the years, but the latest $1 million is the largest single investment from the foundation to date.

“The Hamill Foundation continues to help us raise the bar for nursing education and address the nursing shortage,” Kathryn Tart, founding dean and professor at Gessner College and Humana Endowed Dean's Chair in Nursing, said in a news release. “The enduring commitment and generosity of The Hamill Foundation allow us to answer the call and educate generations of competent and caring nursing professionals.”

Both of the recent gifts help fund UH’s $1 billion Can’t Stop Houston: The Centennial Campaign. As of September, the university had raised more than $881 million. UH turns 100 years old in March 2027.

SpaceX's supersized Starship rocket launches into orbit for first time

Out in Space

SpaceX launched its enormous Starship into orbit for the first time Monday, September 28, and successfully delivered the most advanced Starlink satellites yet, but cut the flight short to ensure safety.

The spacecraft reentered over the Pacific and splashed down north of Hawaii three hours after blasting off from Texas. The company had been aiming for a 10-hour flight, spanning six full laps around Earth, to prove its readiness for NASA’s Artemis moon program.

Starship tipped over and erupted in flames upon splashdown, a dramatic end to the mission.

Elon Musk's Starship almost didn't make it to orbit when one of its engines shut down prematurely. But with everything else working well and the bad engine no longer needed, flight controllers decided, after several tense minutes, to proceed as planned.

“Starship is orbital,” Mission Control announced to cheers.

NASA Administrator Jared Isaacman congratulated SpaceX on reaching orbit and “managing every step in a safe, responsible and especially inspirational way.”

Rocket carries 26 of Musk's most advanced Starlink satellites

Musk’s showpiece rocket — the biggest and most powerful ever built — carried 26 of the latest Starlinks to join the 11,000 older models already providing internet service. They popped out of the spacecraft one by one, drawing more cheers from the SpaceX crowd at the Starbase launch site.

The decision to end the flight early came soon afterward. SpaceX said hours later in an online update that the decision was made “out of an abundance of caution” because of the early engine trouble.

It was Starship’s 14th full-scale launch from Texas’ southern tip in three years. Earlier test flights ventured no farther than the Indian Ocean halfway around the world, often crashing in flames and briefly skimming space.

This time, the intent was for SpaceX to circle the globe from an altitude of 170 miles (275 kilometers) — not just once but six times over almost 10 hours, ending with a Pacific splashdown near Chile. While Starship achieved the proper orbit, zipping along at 17,500 mph (28,000 kph), flight controllers opted to play it safe and bring it back several hours sooner, after just a couple of laps.

The first-stage booster was never meant to return to the Starbase launch site either, dropping instead into the Gulf of Mexico within minutes of the morning liftoff.

SpaceX wants to ensure that everything works before flying Starship back to Starbase. If the spacecraft breaks apart over land and rains debris onto people, “our popularity would diminish very rapidly,” Musk said at a business summit earlier this month. “That’s why we’re being extremely cautious here.”

Depending on the findings from Monday's orbital debut, the next Starship could return to the launch pad, where giant mechanical arms would grab the hovering spacecraft. If the catch works — Musk gives it even or slightly better odds — then SpaceX will refly the spacecraft by year’s end or early next year.

The 407-foot (124-meter) rocket was designed from the start to be fully reusable, a key to lowering launch costs. SpaceX managed to salvage the last Starship from the Indian Ocean in July. Engineers modified the newly launched Starship’s heat shield based on hands-on inspections of the recovered spacecraft, which is being tugged back to Starbase.

SpaceX wants Starship to be certified for orbital flight

SpaceX is pressing hard to certify Starship for orbital flight, a vital step toward moon and Mars travel.

NASA’s Artemis III mission is coming up as soon as next summer, a triple-launch docking exercise in orbit around Earth between an Orion capsule full of astronauts and competing lunar landers. Jeff Bezos’ Blue Moon would blast off first, followed by Orion — which would close in for a linkup — and then Musk’s Starship for a docking with Orion once Blue Moon is unleashed.

The next mission, Artemis IV, is slated for no sooner than 2028 and would have astronauts landing on the moon in either Blue Moon or Starship, whichever is ready first. Subsequent moonshots will alternate between the two billionaires’ landers.

Musk originally developed Starship for Mars, intending to launch scores of them with the red planet’s first settlers. For now, he plans to focus on the moon and use Starship to haul satellites into orbit by the truckload, phasing out the company’s frailer Falcon 9 rocket within several years. A second Starship launch site is nearing completion at Florida’s Kennedy Space Center and a third is planned for Louisiana.

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