How Long Does Prototype Development Take?

Prototype development is a process in which a concept or design is turned into a tangible and working model. With the help of prototypes, you can test usability, design, and functionality before mass production starts. Testing is crucial in product development because it serves as a means to validate your ideas, attract investors, and refine details.

The typical development timeline is as follows:

• Concept and Design (1 to 3 weeks): This is where sketches, CAD (computer-aided design) models, and design specifications are finalized.
• Initial Prototype (2 to 6 weeks): At this stage, a basic model is created using rapid prototyping techniques, such as 3D printing.

• Testing and Feedback (2-4 weeks): The prototype undergoes testing and assessment of its usability, performance, and functionality.
• Revisions and Refinement (2-8 weeks): Based on the testing results, the design is revised and refined. Changes are made to improve the prototype and align it with user needs or manufacturing requirements.
• Final Prototype (1-4 weeks): At this stage, you now have a polished version you can be proud of. The prototype is now ready for investor pitches, market testing, or pre-production.

Prototype development usually takes 2 to 6 months. Simple products can take as short as 4 to 6 weeks to prototype, whereas highly complicated ones can take a year or even more.

Factors that Influence Prototype Timelines

The given timeline, although typical, is not the same for everyone. Several factors affect it.

• Complexity of the Product: Simple products typically require a shorter time to prototype than those with intricate features, such as smart home devices or wearable technology. Complicated products like this can take months to prototype.
• Materials and Processes: The materials used in creating the product, such as whether it is made of metal, plastic, textile, or electronic components, affect development time. Some materials can be easily 3D printed, while others require specialized fabrication and longer lead times.

• Design Revisions: It is rare for the prototype to be the final one. There are usually multiple revisions, changes, and improvements in the form and function before the perfect prototype is created. All these changes and revisions make the process longer.

• Resources and Expertise: A team with its own designers, engineers, and manufacturing partners can move a lot faster than a startup that has to outsource everything.

• Budget: A higher budget allows for simultaneous work on different prototype aspects. This can shorten the timeline. On the contrary, when funds are limited, tasks are often completed in stages, which can extend the timeline.

How to Streamline the Process

• Have a Clear Goal: Be clear about what you want to prove before you start.

• Prioritize Features: Focus on the features first. You do not have to perfect everything at once.
• Leverage Rapid Prototyping: Using 3D printing, virtual stimulations, and modular designs can save you time.

• Work with Experts: Working with experienced engineers and designers can save you from costly mistakes.
• Stay Flexible: Revisions and delays are standard parts of the process. Remember that a prototype is meant to evolve and improve over time.

Seek the Help of Experts Today

Bringing an idea or concept to life is exciting, and prototype development is an important part of this process. While timelines vary, most projects span a few weeks to several months, depending on the factors listed earlier. Moving quickly enough to maintain momentum while ensuring that your prototype is functional, testable, and aligned with your vision will help you in creating the final prototype.

Whether it is a simple product or one that utilizes cutting-edge technology, understanding the process and collaborating with experts who know what they are doing can reduce stress and frustration and increase your chances of a successful product launch.

If you are in the process of product development and need expert help with your prototype, please don’t hesitate to contact us today.

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Our flexible lead wire has a soft, smooth biocompatible PVC jacket that meets USP class VI standards.  It is made of specially compounded and plasticized polyvinyl chloride insulation applied over ultra-fine stranded wire that yields a finished wire with a longer flex life and a higher flexure index level than that attainable with ordinary PVC insulated wire.  This wire ideal for disposable medical devices and other cost sensitive medical applications.  MedFlex Wire is perfect for a wide variety of medical devices that come in contact with the skin, including:

EEG Devices

EMG Devises

Temperature Monitoring Devices

Catheters

Med FlexWire is available from stock in black or grey and gauges 26, 29, and 36AWG, but we will manufacture it for you in a variety of color, size, and stranding configurations.

Please contact us today to discuss your needs.

Custom Disposable Medical Wire & Cable

Calmont is a leading designer and manufacturer of custom disposable medical cables and lead wires. We specialize in designing custom multi-conductor cables, with and without lumens, that have critical dimensional and shape requirements.   We have designed cables for a wide variety of medical cathetars, diagnostic equipment, and monitoring devices where disposable cables are needed.

Our highly efficient, ISO 13485 certified, manufacturing  facility is capable of producing high volume, low cost wire and cable that can be delivered at once, or on a schedule that meets your production requirements.

Contact Us

Contact us today to discuss your medical cable application and let us assist you in designing the right cable for you.

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The Cassini-Huygens spacecraft was launched in October 1997 to study the famous rings and moons around Saturn.  The spacecraft finally reached Saturn and began orbiting the planet nearly seven years later and, today, after 13 years in orbit and 20 years in space, Cassini plunged into Saturn’s atmosphere marking the end of one of the most successful missions in the history of interplanetary exploration.

Most of what we know about Saturn came from Cassini.   Along with countless discoveries, the spacecraft unveiled the structure of Saturn’s rings and it delivered the Huygens probe to the moon Titan which has since been identified as a prime target in the search for life beyond earth.

This morning, Spacecraft Operations Manager Julie Webster called Cassini "a perfect spacecraft" and said "it did exactly what it was supposed to do."

Calmont Wire and Cable is proud to have provided it’s highly flexible and durable Siliflex wire and other custom cables to distribute power and signal to many of the Cassin spacecraft’s operating systems. Calmont Wire and Cable has a long tradition of research and development associated with space travel.   In addition to the Cassini spacecraft, Calmont has supplied Siliflex wire and other custom cables to both NASA and ESA for a large number of programs including:  Apollo, Space Shuttle, Voyager 1 &2 , Hubble Telescope, Mars Rover, Mariner, and Deep Space.

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“Since the wire is often exposed and becomes a formal part of the sculpture it needs to have certain physical properties such as color and flexibility. The high flex silicone insulated wire is perfect since it resists kinking and drapes like string or rope” says Claude.
His challenge was “off the shelf” wire was too stiff and could not be draped and arranged properly. The wire Claude chose is a silicone insulated wire with a high strand count conductor. This is an extremely flexible wire which was easy to incorporate into the art piece. Silicone insulation is used in a variety of industries and applications requiring  super flexible wire, high voltage or high temperature.

The silicone wire was used in a sculpture commissioned by the King County Arts Commission for the exhibition hall at the Brightwater Treatment Facility (pictured top, right).  Happy with the performance and look of the wire, he has been using the silicone wire for other art pieces as well.

The photos below illustrate the layout and a close up of Claude’s sculpture. The silicone wire plays a part in the design and function of the art piece. Not only does the wire have to carry the voltage to power the sculpture it has to have the right color, texture and placement so as to not take away from the piece.

Here’s a video of Diatomoton 5 in action:

Diatomoton5 from Claude Zervas on Vimeo.

About Claude

Claude Zervas’ artwork uses technology and a variety of media to explore representation of landscape, social ecology, and memory. He creates 2D, 3D, and time-based work using video or custom computer programs.  He has stated, “I grew up in a rural part of Whatcom County and I have been greatly influenced by the physical landscape, the social topology, and the transformation of this region. I am interested in how the idea of place evokes emotion, the way emotion affects memory and how memory in turn affects perception.”

After attending art school at Western Washington University Zervas fell into a career as a software engineer, eventually returning to art full-time. He leverages many of the skills acquired from his engineering experience to produce his art. Click here to see more examples of Claude’s art.

If you have questions or an application requiring custom wire or cable contact Calmont for assistance. Please feel free to comment or share this article.

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Silicone insulated wire and cables are a popular choice for a variety of industries due to it’s operating temperature range, extreme flexibility, voltage properties. Silicone wire and cable compounds are available in special grades and formulas are available for specific requirements such as, medical grade/implantable, low smoke/halogen-free, increased resistance to abrasion , flame retardant and more.

Silicone wire advantages include:

• Service temperatures from –50 to +200 °C
• Special grades are available for use in a temperature range from –90 to +300 °C
•  Excellent aging resistance, even under extreme conditions
•  High resistance to many different chemical substances
• Outstanding electrical properties
• Extreme flexibility

Aerospace

Aerospace and space applications often require low smoke halogen-free wire and cable. Silicone insulated cables can be manufactured with low smoke halogen-free grades. Low smoke halogen-free silicone cables offer a advantages over conventional cable products:

• Silicone does not emit any corrosive gases.
• Flame resistance – Ensures reduced flame propagation.
• Halogen-free cables generate little smoke, ensuring clear visibility during fires.

Commonly used Mil-Specs for silicone wire,  is the MIL-W-16878

• MIL-W-16878/7   – Wire, Silicone Insulated, 200°C, 600 Volts.
• MIL-W-16878/8   – Wire, Silicone Insulated, 200°C, 1000 Volts.
• MIL-W-16878/29  – Wire, Silicone Insulated, 150°C, 600 Volts.
• MIL-W-16878/30  – Wire, Silicone Insulated, 150°C, 1000 Volts.
• MIL-W-16878/31  – Wire, Silicone Insulated, 150°C, 1000 Volts, Glass Braid, Abrasion Resistant.
• MIL-W-16878/32  – Wire, Silicone Insulated, 200°C, 1000 Volts, Glass Braid, Abrasion Resistant.
  

Other Mil-Specs using silicone insulated wires with FEP Jacket include MIL-DTL-8777, MS25471 and MS27110.

Medical Applications

Medical device manufactures use silicone insulated wire and cable because can be used in an autoclave, it’s chemical resistance and ultra flexible nature. Silicone is widely used in applications that include medical robotics, implantable, sensors and handheld devices just to name a few. Silicone is also manufactured for medical tubing and is typically used in applications such as catheters, drains, feeding tubes, and peristaltic pumps. Manufacturers considering silicone for these types of applications can choose from special grades that meet stringent health agency requirements.

Automation and Ribbon Cables

Typical ribbon cables are not designed for repetitive flexing. These cables are generally made of PVC which is brittle and not resistant to harsh chemicals. For applications in the automation and robotics industries a cable designed specifically for hi flex applications is needed. Silicone ribbon cables can withstand millions of flex cycles and can be extruded or bonded from as little as two conductors to over twenty and can be manufactured up to 40AWG. Applications such as  multi-axis motion systems, robotic equipment, linear motor stages and packaging equipment all require flexible flat cable designed to achieve reliable performance. Silicone ribbon cables are also used in static installations where a flexible cable is required.

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Tell your custom cable manufacturer all about your robotic application and include:

• The type of movement is required of the wire or cable, number of cycles.
• The environment which it will be operating in. Include temperature, contact with fluids or moisture and abrasion resistance.
• Other requirements such as, voltage, EMI, flammability and any special needs.

The more your custom cable manufacturer knows about your application the better your cable design will be.

Material choices depend on the robotic requirements and begin with the conductors. Conductors (except solid core) are made up of multiple strands of fine wire, the more strands in the construction the more flexible and resistant to flex damage the conductor will be. The use of high strand count  alloy conductors is recommended for high flex cycles and torsion. Alloy materials are stronger than standard copper conductors and can withstand repetitive flexing and vibration. High strand count conductors are available in several types of configurations (view here),  your cable manufacturer can recommend the right one for you.

Insulation and jacket materials also play an important role in the robotic wire or cable’s performance. Selection will depend on the surrounding environment. Silicone insulation and jackets are ideal for chemical resistance, high temperatures and super flexible cable designs. Silicone is not as resistant to abrasion as other materials. Understanding the material properties (view chart)  will help narrow down the choices.

Cable construction also needs to be considered. Cable lay, lay direction, strength  members and type of EMI shield  The wrong type of shield may cause damage to the conductors and compromise   EMI protection   in high flex environments. Consult your custom cable manufacturer for the best solution for your project.

Working closely with a cable manufacturer experienced with robotic cable applications during the design phase, can save you time and money with problems down the line from using a cable not suited for robotic application.

Your comments are welcome. If you enjoyed this article, please share it with your colleagues. If there is something you would like to read about, let us know!

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High voltage wire applications can be found in every industry. High voltage wire and cable doesn’t have to be bulky and stiff.  High voltage lead wire and cables can be manufactured to be extremely flexible wire and cable while meeting high voltage requirements by using high strand conductors and flexible wire insulation and jacket materials. Co-extruded silicone cables also offer low corona, high flexibility while maintaining high voltage properties.

There are several factors which makes a wire or cable  high voltage such as, conductor diameter, insulation material and insulation wall thickness. Corona discharge can damage the wire insulation and must be considered in the design. Ways to reduce damage caused by corona discharge is by reducing the air gaps between insulation and conductor. This is accomplished by adding a semi-conductive “sheath” around the conductor which increases the conductor diameter and reduces the gap between conductor and insulation. C0-extrusion of silicone is a process where the semi-conductive layer is extruded at the same time as the insulating material (pictured) enabling the high voltage wire to be extremely flexible and low corona.

For thinner options for high voltage corona resistant hook up and lead wires can be made with FEP, TFE, and PTFE. Though Silicone hook up wire has excellent dielectric properties and is used in many high voltage applications, it does have a thicker wall thickness than  FEP,TFE, or PTFE. For applications requiring an extremely flexible high voltage wire to be UL certified wire or MIL-SPEC wire, specify UL3239 with silicone or the MIL-W-16878.

High voltage wire and cable can be manufactured in many sizes and configurations for your specific application. You don’t have to settle for off the shelf solutions, custom wire and cable manufacturers take your application and requirements into consideration when designing your cable.

Applications for high voltage wire include:

• MRI machines
• Generators
• Appliances
• Robotics
• Lighting

Every application has it’s unique needs and must be addressed when designing custom cable. A while back we had a customer in the entertainment industry that provides lighting and power to movie sets on location. They needed an extremely flexible high voltage cable that could be easily routed around the movie set while supplying power for the lighting equipment from the generators. The cable needed to be an extremely flexible cable which could withstand abrasion from being dragged on the ground, stepped on and rolled over. Calmont designed a high voltage super flexible cable to meet these requirements using high strand count silicone insulated conductors with a special lay. The outer jacket was made from polyurethane to resist abrasion while being flexible enough to maneuver around the sets. The cables performed excellent and outlasted the previous cables they replaced. Custom cables are manufactured for the type of use they must endure which gives the cables an advantage over off the shelf.

Contact Calmont with your high voltage wire and cable requirement and let us design the perfect cable for your application.

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Silicone insulated wire and cable is an excellent choice for medical cable applications.  Besides being extremely flexible, silicone rubbercan withstand autoclave and other forms of sterilization. Properties that make silicone suitable for medical applications include: Low thermal conductivity, low chemical reactivity, low toxicity and  thermal stability (consistency of properties over a wide temperature range of 100°C to 250°C). Abrasion resistance is a concern when considering silicone insulation or jacket.  Formulas for higher tear strength are available to increase resistance to abrasion.

Applications suitable for silicone cables include:

• Arthroscopic
• Surgical Robotics
• Electrosurgical
• Implantable
• Ophthalmic
• Foot Switch
• Patient Monitoring

What makes a material medical grade? Materials are tested for bio-compatibility and are categorized to be used for medical applications. Medical grade materials are generally grouped into three categories: non implantable, short term implantable and long term implantable. Materials approved as USP Class V and VI can be considered medical grade, most medical grade silicone is at least Class VI certified.

Uses for medical grade silicone cables include:

• Tubing/Lumen
• Drains
• Feeding tubes
• Catheters
• Implants for long and short term use
• Sensors

Co-extruded and multi-layer silicone cables can be used for high voltage applications such as X-Ray and MRI equipment which require electrical noise suppression and limited power loss . Co-extrusion involves extruding a semi-conductive silicone layer around the conductor to remove air thus reducing corona. Extruding both semi-conductive layer and jacket simultaneously insures no air or particles are caught between the layers. Benefits for co-extruded silicone include corona, moisture & ozone resistance, lightweight and flexible cable design, radiation resistance to name a few.

When working with your custom cable manufacturer, it is crucial to provided them as much information as possible about the application, the environment, sterilization and bio-compatibility requirements. The more information you can provide to your silicone cable manufacturer will help in determining if silicone is right for your application and to offer you material choices that will enhance your product’s performance.

Contact Calmont Wire & Cable today for more information or if you have questions regarding medical cables, silicone or material choices for your project.

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