Differences Between A Prototype and A Production Design
In general, prototypes will differ from the final production variant in three fundamental ways:
Materials. Production materials may require manufacturing processes involving higher capital costs than what is practical for prototyping. Instead, engineers or prototyping specialists will attempt to substitute materials with properties that simulate the intended final material.
Processes. Often expensive and time consuming unique tooling is required to fabricate a custom design. Prototypes will often compromise by using more variable processes, repeatable or controlled methods; substandard, inefficient, or substandard technology sources; or insufficient testing for technology maturity.
Lower fidelity. Final production designs often require extensive effort to capture high volume manufacturing detail. Such detail is generally unwarranted for prototypes as some refinement to the design is to be expected. Often prototypes are built using very limited engineering detail as compared to final production intent, which often uses statistical process controls and rigorous testing.
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