We hear this a lot:
“We just need one prototype, then we’ll be ready for production.”
Or later in the project:
“The product is done. Let’s make the tooling and get into manufacturing.”
These assumptions are common, and they’re almost always wrong.
If you’re developing a new hardware product, especially something complex or custom, it’s important to understand how much work still lies ahead. Not just in terms of time and money, but in terms of how many steps are needed before you can reliably produce at scale.
Let’s break it down.
The “One Prototype” Trap
When hardware companies first start working on a new product, they often ask for a single prototype.
In their minds, that prototype will:
- Look close to the final product
- Work well enough to test
- Be a big step toward production
That’s rarely how it goes.
The first prototype is just the beginning. It helps identify issues with the design, the mechanical fit, user experience, and more. In most cases, it’s far from final.
What usually happens is that first-time product developers can only foresee the first prototype iteration and not beyond it, which is shown in this image:
For moderately to very complex products, you’ll need multiple prototyping rounds, Proto 2, Proto 3, sometimes up to 5 or more, before the design is stable and ready for manufacturing. Each version teaches you something new. This is especially true for innovative products or if you’re using new technology, materials, or mechanical assemblies.
However, it’s also important to note that for simple products, the development is more straightforward than the graphic above.
Still, many hardware startups budget and plan as if only one prototype is needed. That’s a mistake.
“The Product Is Done” (But It Isn’t)
Another common misunderstanding happens later.
Once the prototype is working well, teams often assume the rest will go quickly. They think:
“Let’s make the tooling and start producing.”
But this ignores what comes next: the industrialization phase.
That’s where you move from product design to process design. You’re not just making one unit anymore; you need to make thousands, consistently.
Here’s what that industrialization phase looks like for most moderately to very complex products:
It includes:
- Tooling trials
- Compliance testing
- Pre-production runs
- Design for manufacturing (DFM) changes
- Validation of fixtures, jigs, and processes
- Debugging assembly steps
And it often takes as long as product development itself. In some cases, it costs more.
Again, important to note that for products that are simple to manufacture, industrialization is usually faster and less chaotic than you see in the graphic above.
The goal isn’t just to make a good product, it’s to make it repeatably, at scale, without surprises. That takes serious engineering work and coordination.
Why This Gets Overlooked
There are a few reasons:
- If you haven’t been through hardware product development before, it’s hard to picture all the steps.
- A working prototype gives a false sense of completion.
- The complexity of tooling and manufacturing isn’t obvious until problems start showing up in early production.
- Some companies don’t even realize there’s a difference between “development” and “industrialization.” However, skipping or rushing the industrialization phase often leads to quality issues, missed timelines, and high costs down the line.
What You Should Do Instead
Here’s what we advise hardware companies bringing a new product to market:
- Plan for several rounds of prototyping, minimum. Don’t expect to get it right on the first try.
- Treat industrialization as its own project. It needs a separate plan, team, and budget.
- Run pilot production batches. You’ll find a lot of issues before you hit mass production, and that’s a good thing.
The more you embrace this process, the fewer nasty surprises you’ll get later.
The Bottom Line
The road from idea to production is long, and that’s normal. If you’re launching a new product, be realistic. Plan for iterations. Budget for process development. And work with people who’ve done this before (you can ask us if you like!).
It’ll save you a lot of time, stress, and money.
Further reading
- The Need For Many Prototypes [FIGO Case Study]: FIGO’s founder Robert Nappi emphasizes that launching the innovative sous‑vide-and-refrigeration device took over six years and thousands of prototype iterations to ensure not only technical performance (rapid cooling and reliable cooking) but also user experience, manufacturing readiness, and aesthetic appeal.
