In our previous article, we explored how sketching remains an invaluable tool in the modern product designer's toolkit. Today, we're taking the next logical step in the design process: physical prototyping.

While digital tools have revolutionized product development, there's something irreplaceable about holding a physical representation of your concept in your hands.It’s always surprising how many insights are uncovered during that transition from 2D sketch to 3D prototype. In fact, our Founder, Stuart has a phrase he often uses:

“If a picture is worth a thousand words, then a prototype is worth a thousand pictures.”

In this post, we’ll explore why physical prototyping continues to be crucial in creating successful products, and how different fidelity levels serve distinct purposes throughout the design journey. In an age of sophisticated CAD modeling and virtual reality, you might wonder if physical prototyping is becoming obsolete. Our reply would be a resounding no - and here are just some of the reasons why:

1. Visceral Understanding

There's a fundamental difference between seeing something on screen and holding it in your hands. Physical prototypes engage multiple senses simultaneously—touch, sight, and sometimes sound or smell—creating a more complete understanding of how users will experience your product.

2. Unexpected Discoveries

Digital simulations are only as good as their programming. Physical prototypes often reveal unforeseen issues or opportunities that no simulation could predict—a slightly awkward grip, an unexpected material interaction, or an ergonomic insight that becomes obvious only when physically handled.

3. Communication Tool

Like sketches, physical prototypes serve as powerful communication tools across teams. Engineers, marketers, executives, and users can all interact with the same object, creating a shared reference point that transcends professional jargon or technical specifications.

4. User Testing Reality

User testing with physical prototypes provides insights that digital mockups simply cannot. Watching someone struggle to open your packaging or seeing their delight as a mechanism clicks into place offers invaluable feedback that informs refinement.

What are the different types of prototypes?

Different stages of the design process call for different levels of prototype fidelity and at Prime Studio we employ multiple different prototyping methods depending on the needs and stage of the project.

Low-Fidelity Prototypes

Materials: Cardboard, foam core, foam, paper, tape, glue, armature wire

Time investment: Minutes to hours

Purpose: Exploring form, basic ergonomics, and rough proportions

Low-fidelity prototypes are the physical extension of your sketches. These quick, rough models help you rapidly test multiple concepts without significant investment. They're perfect for early ideation when you're still defining the general direction of your product.

We’ll often use “bread-board” prototypes to check the validity of a mechanism, and hand-made foam models are a great way to check and refine form and proportions in real time.

Low fidelity prototypes are not only for internal evaluation, though - sometimes they form the basis of a Phase 1 presentation, especially on packaging projects where it’s important for the client to understand the unboxing experience.

Medium-Fidelity Prototypes

Materials: 3D printed parts, simple mechanisms, CNC metal, Cast urethane, laser cut cardboard

Time investment: Hours to days 

Purpose: Testing specific features, refinement of form, basic functionality, consumer testing

Medium-fidelity prototypes bridge the gap between concept and reality. We use them to focus on aspects of a design that need validation, whether it's a mechanism, an interaction, a particular element of the form - or sometimes to give clients a feel for the overall product or package design.

Laser cut cardboard allows us to perform preliminary ship and drop testing for packaging projects whereas SLS 3D prints give a good representation of blow-molded bottles and are useful for assessing the ergonomics of a filled structural package.

Finally medium fidelity prototypes are often used for consumer testing, especially in a focus group setting, to expose consumers to a range of concepts to hear their feedback.

High-Fidelity Prototypes

Materials: Production-intent materials, functional electronics, refined finishes 

Time investment: Days to weeks

Purpose: Final validation, user testing, stakeholder presentation, marketing

High-fidelity prototypes both look and function as close as possible to the final product. They are often the last step in the design sign-off process before committing to mass production tooling and processes.

They can be expensive to produce but they have many uses including key leadership sign-off, investor presentations and for photography for marketing and packaging purposes. And it’s worth remembering that catching an issue on a prototype is always cheaper than catching it in mass production.

Appearance Models

Materials: Similar to high-fidelity prototypes but focused on look and feel and exterior finish 

Time investment: Days to weeks 

Purpose: Visual presentation, market testing, photography

A special category worth mentioning is the appearance model—a prototype that looks identical to the final product but may have limited or no functionality. These are particularly valuable for stakeholder presentations and market testing when the visual and tactile experience matters most and are often used for photography purposes.

Selecting the appropriate prototype fidelity at different project stages is a nuanced decision that balances several factors:

Information needed: What specific questions are you trying to answer?

Time constraints: How quickly do you need feedback?

Budget limitations: What resources can you allocate to this stage?

Audience: Who will be evaluating the prototype?

The key is matching the prototype's fidelity to your current needs. Creating a high-fidelity prototype too early wastes resources and budget on details that may change, while low-fidelity prototypes are generally insufficient for final validation, and also consumers may not understand that they are not made from production materials etc... Effective product development processes use multiple rounds of prototyping at increasing fidelity levels. Each prototype answers specific questions and, in turn, generates new ones.

Modern product design isn't about choosing between digital and physical prototyping—it's about leveraging both strategically. Digital 3D tools complement physical prototyping rather than replace it.

Much like sketching, physical prototyping is a timeless practice that transcends technological trends. The tools and materials may evolve, but the fundamental value remains: nothing quite replaces the moment when a concept becomes something you can hold, use, and experience.

And finally, a big shout-out to the unsung heroes - our prototyping vendor partners. It’s so, so important to build a relationship with them. They bring years of experience to the table and will often guide us on the appropriate prototyping methods and materials to get to the desired end result. We work closely with our manufacturing vendors and value their input - the same applies to our prototyping vendors.

Any questions about this article or on different prototyping techniques - just drop us a line at contact@primestudio.com.

Summary

At Prime Studio, physical models are key to refining designs beyond the screen. From rough early forms to near-final builds, different levels of fidelity help test ideas, gather feedback, and reveal what digital tools can’t. By engaging the senses and uncovering the unexpected, prototyping sharpens communication, speeds iteration, and leads to better product.