Oct 23/25

Prototype Testing: The Key to Automotive Innovation

 

  • Early prototype testing allows you to validate designs without resorting to expensive late corrections.
  • Having a structured testing plan with clear pass criteria enables leaders to quickly approve results.
  • Starting digital allows you to iterate faster and get to the next step in your process with a model that’s further along.

As the prototype testing phase reduces launch risks, it has proven itself to be a critical step in the effort to make better development decisions.

Mayco International employs this method as part of its development process, with tooling and testing under one roof, to ensure a seamless automotive testing process.

What is Prototype Testing in Automotive Development?

By testing prototypes early and often, you can quickly prove that a design will or will not meet requirements when it comes to areas such as:

  • Function
  • Safety
  • Simplicity to produce
  • Strength
  • Build targets

It can support your automotive innovation efforts by enabling you to present critical data that proves whether a particular design is worth the investment. Then you can start mass production of your design with less risk, confident that issues have been identified and resolved well before rollout.

What Is the Main Purpose of Prototype Testing in Vehicle Programs?

Prototype testing in vehicle programs helps ensure that your ideas and assumptions are accurate before any item goes into production. As such, you can gain benefits in terms of time, money spent, and even safety.

Ways you can achieve these benefits include:

  • Reducing unknowns during production
  • Presenting key measurements instead of assumptions
  • Supporting objective decisions with data
  • Revealing integration issues with parts or software
  • Raising process issues before production starts
  • Shortening the time to mass production by reducing later iterations
  • Ensuring greater design accuracy with pre-iterated designs

Over time, this will increase your “Right first time” rate, reducing complaints and reworks.

Prototype Testing Stages

While different projects may require different methods, the prototype testing process typically starts with creating and running simulations. Performing as many steps as possible digitally, including measuring how long it takes to manufacture, allows you to make faster iterations without needing to tool a single item.

After the digital step, you can take the models developed in software and 3D print them or otherwise create physical versions of them. You can then quickly learn their capabilities with a range of materials.

Building “mules” (test vehicles or rigs) allows you to iterate and test smaller parts, so long as these vehicles provide an accurate representation of real conditions.

Once your test data meets all key performance goals, you can freeze the design and move to the next step in your process.

Ensuring Prototyping Works

Make sure your next build effort aligns with a single question, so each prototype testing effort pushes you in a clear direction. Mayco International can help with this effort, with our experience in targeting prototyping and knowing when to escalate issues to ensure you reach your goals with as few complications as possible.

To learn more about how our advanced tooling capabilities help you iterate faster, get in touch today. Discover how our proven logistics process and system expertise can boost your manufacturing end-to-end.

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