Aerospace Standard Prototyping...

Prototype Design Consultancy

Flynn Product Design can guide you through the different stages your concept will require, and we will use our experience to prototype at the right level for your project, ensuring you have the right quality of prototype required for its specific purpose. A prototype brings your product to life. It adds value by proving that your designs are functional, are intuitive to use and feel right. A design prototype provides an essential opportunity to evaluate the product design, and gain invaluable feedback through testing.



Prototyping Capability / Frequency of use in project workflow

Precision CNC in Plastics and Metals

FDM ( Filament Deposit Modelling ) 3D Printing in PLA/PP/PET/HDPE/PA/GFPA/Woodfill/Metal Fill

3D Printing SLA ( Stereo Lithography )

3D Printing SLS ( Selective Laser Sintering )

3D Printing Metals ( Powder Sintered Metalergy )

Vaccuum Casting Polyurethane simulants – Pre tooling in Silicone

RIM ( Reaction injection moulding )



How is a prototype useful for licensing?

Prototype development is not strictly essential but can add value to a project and be useful in distinguishing any industrial design issues. Prototypes can be useful if you need to demonstrate that the concept works. A simple proof-of-concept prototype would be sufficient to demonstrate the basic fundamentals of the design. A more sophisticated prototype can strengthen your presentation, particularly if you need to show your product to investors, manufacturers etc. If you are looking for a third party to licence an idea, you need to convince them it works. That it is worth their investment in licensing as well as demonstrate that its a marketable, engaging product. If that is applicable. If you are licensing a technology or mechanism, then proof of concept engineering prototype assemblies will often suffice. But either way, it is far more persuasive than a simple patent application or sketch.

proto HMD

Proof-of-concept prototype

A proof-of-concept prototype is solely designed to showcase the technical workings of the design and the core functionality of the product. This type of prototype is not centred around the visual look or quality the product, however, many decades of engineering know-how will go into our proof of concept prototypes, which can demonstrate that a particular design fulfils its intended purpose and meets specified criteria consistent with “the solution”. End-use materials and aesthetic appeal will be considered further down the line.

Proto Helmet mounted

Presentation prototype

A presentation prototype is a functioning model that showcases the end use materials and finish as well as core functionality and mechanisms required to make the product work, and the overall look and visual design. Presentation prototyping can be so convincing that some companies go into short-run manufacture using these techniques. Two-part reactive polyurethanes can be used to create materials in thin wall assemblies which are subsequently cast inside a vacuum. This takes place in silicone tooling. The end result sometimes can be indistinguishable from a finished product. Entrepreneurs use this to go to board meetings with stakeholders and seek stage funding prior to manufacture. Some companies actually launch products using these techniques. To lead into soft manufacture before full production is ramped up. This prototype will usually consist of a mix of production grade materials mimicking design quality whilst making efforts to keep costs down. This prototype is a good way to show product viability before mass manufacturing takes place as part of the product design consultancy process.

The Process

Our skilled craftspeople and engineers work meticulously to create the very best in prototyping from VAC and RIM Casting to FDM, SLA, SLS and Metal Sintering used in Aerospace, but there are different types of prototype depending on the aims. For example, The purpose of a visual prototype is to showcase the form, dimensions and possibly colours of the design as well as to study things like ergonomics, look feel, weight and balance. Mostly a visual mockup or sketch model is created early on in the concept development phase of the product design cycle. as it is not intended to be functional at this stage but can often act as a proof of concept.

Managing Prototyping Budgets..

As well as offering you a full range of prototyping technologies, working to the highest standards, as a front loaded expense development can be costly,  In particular Physical Prototyping can challenge a budget, part of our commitment to manage your investment in design and development we look to reduce high-cost physical prototyping to a level that suits your development budget, as product designers we can use Virtual prototyping up to a point which can reduce expense.

We find it works best for all parties, to develop costs for prototyping once a CAD Data and material specification exists, so we do not take wild estimates, instead offer you fixed costs, tailored to your budgets.