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The Prototype Playbook

A guide to mechanical prototyping and low-volume builds, from EVT to production launch. The frameworks, cost breakdowns, and DFM rules we wish every team had before their first build.

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Why it matters

Four numbers worth knowing before you build anything

70-80%
of a product's manufacturing cost is locked in during design
3-8
prototype loops before most hardware is production-ready
10x
roughly the cost multiplier at each stage, from design to prototyping to production to shipped
70%+
of hardware startups never reach mass production

What's inside

Sections covering the full path from concept to mass production, built from real build costs, validation timelines, and the DFM rules that actually matter at each stage.

01 / THE FRAMEWORK
The framework
The path from concept to mass production, and the stages your build moves through.
02 / EXAMPLE
Example of a part
A real part, priced across laser cutting, 3D printing, CNC machining, and vacuum casting.
03 / DFM
DFM for prototypes vs. production
Why the rules change by stage, and the questions to ask at each one.
04 / WHERE IT BREAKS
Where it breaks
The most common, avoidable ways prototyping timelines and budgets blow up.
05 / BEST PRACTICES
Best practices & timeline
The things to get right early, and a realistic 12-18 month roadmap.
06 / VALIDATION STAGES
Validation stages
EVT, DVT, and PVT at a glance, and what has to be true before you advance to the next stage.

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