Teams that treat prototype success as production readiness often burn six figures on retool. A clear prototype to production injection molding roadmap sets material, gate strategy, and steel timing before the board approves launch.
Four phases OEMs should document
| Phase | Goal | Typical output |
|---|---|---|
| 1. Concept | Feasibility | 3D print / CNC, material shortlist |
| 2. Design validation | Fit & function | Prototype mold or soft tool |
| 3. DFM release | Moldability locked | Written DFM sign-off |
| 4. Production | Scale & repeatability | Multi-cavity steel, FAI, ramp plan |
Where programs stall
- Prototype material ≠ production grade → re-validation delay
- Prototype gate ≠ production gate → warp and cosmetic shift
- No transfer doc from prototype shop to contract molder
- Marketing date assumes production steel in 4 weeks
Deuchi links prototyping recommendations to planned production tooling when engaged early.
Decision: bridge tool or jump to production steel
Bridge tools buy time for market test; production steel wins on piece cost above ~20k–50k annual parts depending on complexity. Model both in TCO.
Handoff package for your contract manufacturer
- Approved STEP revision + change log
- Prototype samples marked good/bad
- Material lot records from validation builds
- CTQ list and cosmetic masters
- Known issues list from prototype phase
FAQ
Can Deuchi take over mid-program?
Yes — we review prior tooling and samples; may recommend new steel if cavitation or process gap is too large.
When should we sign a contract manufacturer?
Before production steel PO — ideally at phase 2 exit when DFM confirms moldability.
Next step: Book a prototype-to-production review with your timeline and volume.