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Parts and Product Prototyping

An effective prototype will help you both evaluate a design and provide valuable feedback on the performance of processes used in the construction of a product idea - including welding, joining and inspection. Where required, this can help de-risk and optimise manufacturing process introduction.

Our intellectual property team are happy to provide searches and advise on routes to protect your ideas. We can also assist in the generation of funding, creating customer confidence and enabling potential manufacturing and life cycle costs to be calculated.

Our extensive laboratory facilities enable products to be assembled, from very small geometry electronics and medical diagnostics devices to large power generation and cooling systems. Engineering expertise in welding, joining and additive manufacturing processes support the application of these technologies. Additive manufacturing, for example, is frequently used with 3D computer aided design (CAD) for rapid prototyping of a part, model or assembly. 

Prototype production

If you already have a clear design brief, we can project manage and deliver a prototype, bringing your idea to life with a physical prototype and leaving your engineering team free to explore other avenues of interest.

TWI’s national and international networks also enable us to source suitable suppliers of materials, machining, assembly, inspection and control equipment.

Press Releases

Find out more about parts and product prototyping:

Core Research Programme (CRP) and Joint Industry Projects (JIP)

Core Research

Each year the TWI Core Research Programme (CRP) addresses challenges on behalf of our Industrial Members as well as developing specific technologies and processes. Each of the projects under the CRP is focussed on engineering, materials or manufacturing technologies.

Find out more here

Joint Industry Projects

TWI also conducts Joint Industry Projects (JIPs) that bring together groups of Industrial Members to share the cost of research activities in areas of mutual industrial interest, gaining exclusive access to the outcomes. These projects cover a broad range of topics.

Find out more here

Steps in the Prototyping Process

Whichever type of prototyping is used, it is an important part of the product development process, allowing designers to test, refine and develop their ideas before committing to a final product. The prototyping process is commonly broken down into five steps:

  • Defining the vision: This step includes setting goals and objectives for the prototype
  • Key features: Once the objectives have been determined, designers focus on key features that need to be included in the prototype to achieve these aims
  • Prototype production: This step involves the creation of a fully functional working model of a product or system. This can include anything from basic paper prototypes through to digital or physical models
  • Testing and refining: Once created, a prototype is tested and refined until it meets the goals set out in step one. This can include user testing, feedback and further development to allow for more improvements
  • Presenting and approval: Once the testing and refinement of the prototype is complete it is typically presented to stakeholders so that approval can be gained for the final product development for the target audience

Whichever types of prototypes are created, these five steps allow designers to ensure products meet their required objectives before committing time and resources into developing a final real world version. Using prototyping tools to turn a visual representation into a high fidelity prototype allows for user interaction and testing in the early stages of a product before committing to a final design.

Benefits of Prototyping

The most obvious benefit of prototyping involves being able to create early versions of products so they can be tested and developed before a final design is created. However, there are several other benefits to prototyping too:

  • Improved Product Design – including the early detection and testing of potential design and manufacturing issues ahead of mass production
  • Faster Time to Market – prototyping allows products to reach the market sooner through testing on inexpensive physical or digital iterations
  • Reduced Costs – these costs include both physical and time-related costs
  • Improved User Experience / Customer Satisfaction – testing and refining a design with functional prototypes prevents problems from occurring that could harm your brand when a product reaches the market, while also ensuring the product meets its objectives
  • Improved Communication and Collaboration – an often overlooked benefit of prototyping is how it ensures stakeholders, developers and managers are aligned in their goals. This allows for buy-in from investors and makes sure teams are working towards the same goals

Prototyping within a Development Programme

We can offer assembly, testing and assistance in developing a route to manufacturing as part of an overall  technology acquisition programme.

Our capabilities for prototype delivery include design and machining using the latest CAD design tools and advanced engineering facilities. We have internationally recognised specialist manufacturing expertise including:

  • Numerical modelling and simulation
  • Materials engineering (including: metals, polymers, ceramics, glass, composites)
  • Joining, coating and material processing
  • Product performance and structural integrity
  • Inspection (destructive and non-destructive)
  • Software development, programming and control systems
  • Test and validation

TWI is also able to advise and help in the writing process for funding applications for UK and European programmes. We have a dedicated department for the management of this type of project, which de-risks and eases the application process and work programme.

TWI is committed to delivering high quality projects, and we seek to continuously improve our value to Members. To achieve these aims, we conduct our work within a formalised Quality Management System which complies with BS EN ISO 9001:2008, BS EN ISO/IEC 17025:2005 and the requirement of LRQA, UKAS, PCN, CSWIP and BINDT accreditation services.

Related Case Studies

If you require further information on how TWI can help to develop your idea or product, please email contactus@twi.co.uk.

For more information please email:


contactus@twi.co.uk