Sheet Metal Prototyping: Why It’s an Essential Part of the Design Process


Sheet metal fabrication has evolved massively from its roots in history. Technological innovations have turned this traditional skill into a high-tech process, particularly with the invention of CAD and 3D CAD systems.

But, while 3D CAD software is a powerful tool in the design process, there’s no substitute for an actual, live prototype of your part.

Prototyping is an essential part of the design process for several reasons. In this blog, we’ll explore why you should create prototypes of your sheet metal fabrication designs and the advantages that prototyping can bring.

What is Prototyping?

Prototyping is a great way to bring your ideas to life. It allows you to test your designs and see how they work in the real world. It also helps you to get feedback from others, so you can refine your designs before committing to them.

Prototypes can be simple or complex and made using various materials. The most important thing is that they help you to achieve your goals. Whether you’re designing a new product or developing a new feature for an existing one, prototyping is an essential part of the process.

Why should you invest in a prototype?

There are many reasons for creating a prototype of your design before going into full-scale manufacture:

Design Verification

Designers often use prototypes to test out their ideas before committing to a final design. This can be especially helpful when working on complex products or systems. By creating a prototype, designers can get feedback on the overall concept and how well individual components work together. This feedback can help to validate the design and identify any potential problems.

In addition, prototypes can test different manufacturing processes and materials. This helps ensure that the final product meets all the necessary specifications.

Functional Testing

Functional testing is vital for ensuring that a prototype part will actually perform as intended. Without functional testing, there would be no way to know if a design flaw would cause the part to fail in its intended application.

Functional testing allows engineers to catch these potential problems early on before they cause any costly delays or damage. Plus, functional testing can help to identify opportunities for improvement. For example, a test might reveal a particular material unsuitable for the intended purpose. By conducting functional testing, engineers can ensure that their prototype parts are up to the task.

User Testing

When creating a new product, it’s crucial to think about the user experience. How will users interact with your product? Will they be able to figure out how to use it? Are there any potential problems that could arise?

User testing can help you answer these questions and identify potential issues. By creating a prototype and asking people to use it, you can get feedback on the design, function, and user experience. This feedback can then be used to improve the design before the final product is released.

Design for Manufacture

When it comes to product development, the devil is in the details—literally. To avoid costly errors during mass production, it is essential to design parts with manufacturability in mind. This process, known as Design for Manufacture (DFM), involves considering the manufacturing process’s limitations when designing a part.

There are a lot of different factors to consider when you’re designing for manufacture, but some of the most important ones are material selection, tolerances, surface finish, and assembly. By creating a prototype, engineers can test different designs and evaluate which one will be the most efficient and cost-effective to produce on a larger scale.


Prototyping is an essential part of the product development process. It allows designers to test their ideas, get user feedback, and identify potential manufacturing problems. Plus, it’s a great way to improve the design before committing to full-scale production. So if you’re working on a new product or system, invest in a prototype. It could save you a lot of time and money in the long run.

Need some help with a prototype for your sheet metal fabrication? Talk to our design team to start the process.