The Discovery-driven Prototype Process: Steps and Insights

Creating a prototype is a critical step in the product development lifecycle. It helps us validate concepts, test functionality, and ensure that the final product meets user needs. A discovery-driven approach is essential to guide this process effectively. Let's explore how we can leverage this method to create a successful prototype.

Discovery First: The Initial Step

The first essential step when beginning to create a prototype is discovery. This involves thoroughly researching the problem, understanding user needs, and validating the concept. This initial phase is crucial because it determines whether the concept is viable and if it aligns with market demands. A prototype at this stage, often called a low-fidelity, is a rough, rapid version of the product. It’s created to explore ideas and gather feedback.

Creating a High-fidelity Prototype

A prototype hi-fidelity for a digital software app is a more polished version. It's designed to confirm that the user interface works as intended and that the software functions seamlessly. This prototype is used to simulate real-world usage and user interactions, ensuring that the product meets the user's expectations.

Prototyping Use Cases

Once the initial high-fidelity prototype is created, the next step is to prototyping use cases. This involves creating specific scenarios to test various functionalities of the product. These use cases help identify any potential issues or areas for improvement before the final product is delivered. By systematically testing these scenarios, we can ensure that the product delivers the desired outcomes.

Example: Designing a Medical Device Handle

For a medical device handle, the first step is to decide what the prototype will accomplish. As an example, let's consider the design of a handle for a probe used in medical procedures. The initial question that arose was how to capture the wire, given that the device is disposable and cost is a critical factor. Our team proposed using ribs on both halves to create a twisting path, ensuring easy and secure capture.

A simple model was created and 3D printed on a MakerBot quality printer. This early version helped us verify the design. Eventually, a higher quality 3D print of the finished design was produced using a Stratasys Polyjet printer, creating a functional part that was presented to the customer for testing with their system. This presented a locally machined probe and PCB’s that were hand soldered. This specific prototype was considered a traditional prototype as it was essentially a version of the future production part.

Another Example: Telecommunications Paging System

In another example, when redesigning a telecommunications paging system in the early 1990s, the focus was on creating a more capable microcontroller that could eliminate several support chips. The initial prototype was simply the processor section, designed to verify the updated code. It was essentially a daughter board connected to the existing product's PCB via jumper wires.

The second generation of the prototype involved ordering a small batch of prototype boards to verify the layout for the entire main PCB. This hands-on approach ensured that the design was robust and would function as intended in the final product.

Prototyping Handcrafted vs. Machine-made Products

Prototypes can be hand-crafted, unlike mass-produced products made on a production line. If you're building a hardware product, you must create the circuits, develop the code, and assemble the mechanical elements. If you're working alone, you might need to hide in a cubicle and build things by hand, relying on bare-bones resources. If you're creating a software product, you will likely spend several months coding before your artifact emerges, followed by the final product and market validation.

Conclusion

The success of a prototype depends on a clear understanding of the problem, user needs, and the concept being tested. A discovery-driven approach ensures that the prototype meets its intended purpose and provides valuable feedback. Whether it's a handle for a medical probe or a paging system, the right prototype can be the key to a successful product development process.