How to Turn Your Concept Into a Prototype?

Synced0 asks: "Like a lot of people who post/read on this site, I am a software developer. I have experience developing handheld applications and am quite knowledgeable about the hardware that are in various handheld devices , these days. I have been toying around with the idea of building a device that is based on a handheld platform. I have the basics for what I need such as what OS, and platform I will base it on (motherboard, CPU, storage, display panel, etc). The biggest question in my head is where do I go for the actual design of casing, and who I can get to do the final hardware design. I have never designed hardware before, but now that I have my platform and such, where do I go from here? I have some ideas on what the device should look like, but I have no skills of molding plastics. I have all the pieces working on the desk but am clueless how I progress from this stage.Is it very expensive for someone to take concept into a prototype?"

Re:Some answers

[WhyCause]

One thing to note, here.

Before you submit your plans to a molding shop or machine shop. have someone who knows something look at them! Yes, it is easy to draw something and have it made, but someone who has gone through this process a couple of times will be able to spot common pitfalls that most new designers fall into, namely:

• Tolerances far too tight - nothing will move if you have everything too snug, and machine shops start doubling prices for every extra significant figure on those tolerances.
• Your parts may not actually be manufacturable - if a machinist or CNC machine can't get to a place to cut away material, you just plain can't make the part.
• You have more than one part to be made - one case is likely composed of multiple 'parts', at the very least a front and back half, and if you don't split them out, you'll get one solid chunk back, not the smooth open/close mechanism you expected.
• You might not be able to put everything together - Tab A might fit into Slot B in your head, but if the tolerances aren't correct, or if you just goofed, the real parts won't go together like you think.
• Your cool design might be buildable, but not manufacturable - rapid prototyping machines can easily make things that are otherwise unmakeable; everything looks great for real production until the machinist/molder laughs you out of his office.

...they commonly have this device that can create any solid plastic shape in 3D using lasers

mnmn is referring here to a rapid prototyping machine, which is a really slick option for early prototypes because of the rapid turn-around time. CNC machines might be a second option, since the parts they make will be durable and very solid (unlike a rapid prototyping machine's output). At my undergraduate institution, we had a rapid prototyping machine (one of the first in the nation at university, by the way), and they would sell time on the machine to individuals/companies who wanted to have things made (Remington Firearms was a steady customer, if I recall correctly). I would suggest asking around at the local Mechanical Engineering departments if I were you, since they are likely to be much less expensive than a professional firm, and much more forgiving of design errors. They will also have access to CNC machines that they may be willing to sell you time on, provided you buy the materials and have everything ready to go (CNC machines don't just take 3D model files, you have to specify cutting paths, depths, and cut orders).

All in all, I'd suggest going to a bar near the local university on a Friday afternoon and waiting for the Mechanical or Industrial Engineering graduate students (they won't be hanging out together) to show up. Start talking with them or buy a few rounds, and they'll have better specific information for you.

Re:Thats what I was going to do

[Osty]

I have a design for a device that is inevitable, and could be made with today's technology. The problem is that I have no idea how to get a patent, it just seems to complex for me to figure out.

Assuming you're filing in the US, you can do it all online [uspto.gov]. I've not done it personally, so I have no idea how easy or difficult it actually is, but you should be able to find enough information [uspto.gov] to get it done if you really wanted to.

Check the yellow pages

[MadEE]

When I have been on projects where money has been an issue I typically go to local plastic injection mould manufactures, usually the smaller the shop the better luck I have and simply talk to them about the project. Unless they are swamped with work they are usually very helpful and I have even on a few occasions had them make me a prototype case for next to nothing. After all these guys know you do need financing make things a reality. A single injection mould will cost you around $250,000 depending on the size and complexity. Really nothing beats being able to meet someone face to face with your ideas and concepts you will be surprised at all the cool stuff these guys can do with plastics.

local high-school?

[corychristison]

I'm not sure about anywhere else in the world, but in the city I live in [in SK, Canada] we have a high-school that offers Machining and a school that offers Plastics. Generally you can go to the school and get what you need done [assuming you can do the CAD side of it yourself]
Just go to the school and see if they have any students looking to make a bit a cash. :-)

Big Blue Saw

[chroma]

You should check us out. We currently offer waterjet cutting, which is cheaper than many of the processes listed in this thread.

Re:Two words...

[Anonymous Coward]

Mouser Electronics Inc. www.mouser.com

They have about everything you need, most of it dirt-cheap (not everything though!) Make sure to look at the catalog page (PDF, or hard copy) and not just the website, since prices on idential items will range depending on the manufacturer.

Identical quad op-amps could cost $0.07-3.00 as i recall (different manufacturers, same specs)

they don't have minimums to order on most parts, and the shipping is flat.

Re:Some answers

[Xiroth]

Or better yet, see if you can find where the Industrial Design students hang out. You can either chat with them or even pay one to design it for you - most of the time, the competition for jobs in the field is fierce, so you should be able to pay a graduate student peanuts for reasonably good work.

Re:Four Easy steps

[Anonymous Coward]

You almost got it right.

1) Talk to an intellectual property lawyer (look in the phone book or get a personal recommendation). There is more to IP than patents, he or she will be able to advise you on patents, design rights, copyrights, trademarks et al.

2) Avoid "Invention promotion" companies who promise to put you in touch with "teh profit". Again just look in the phone book, trade journals or ask for a recommendation for proper product development companies.

3) Ensure that the development company respects your intellectual property from step 1. There are likely to be contracts and non-disclosure agreements (especially useful if your patent application hasn't been searched and published yet). Again your lawyer from step 1 can help you.

4) Depending on who develops your prototype there are likely to be many false starts, iterations and evolutions. This will take time. Keep an eye on the competition. Develop unique selling points. Measure the market. What are the costs of manufacture? What is a likely selling cost? Will a big name be interested in a license?

5) Profit is never guaranteed!

Re:Here's a partial answer

[sm4kxd]

I've thought about using emachineshop.com a few times on a few other projects and specialty car parts. I have been quite satisfied with the work I have had them do in the past.

However, the issue that may arrise here is (at least at the time I was going to use them for a unique project) in the process of using them, you agree that the designs you submit to them become their property. If he is trying to build a prototype, using emachineshop.com effectively hands the rights to the design to someone else.

I can't seem to locate the fine print on the site now, maybe their policy has changed. Worth a phone call, at the very least.