When looking at the traditional process of designing an enclosure for a physical product, most industrial design teams follow a familiar sequence: hand sketches, visualizations, rough 3D models, and renders, which are then presented to the client. However, teams often overlook the importance of physical prototyping in the rush to speed up development. Instead, they focus heavily on sketches and digital models while neglecting hands-on exploration in physical space.
Now, imagine walking into a client meeting with only polished renders. While impressive, nothing sparks discussion quite like a physical prototype. The conversation shifts when you place a tangible model of the future product on the table. Everyone in the room wants to touch, examine, and, most importantly, share their thoughts. This kind of hands-on feedback is invaluable — and often impossible to get from digital images alone. In our experience, clients always provide more meaningful input when physically interacting with a model rather than just looking at a render.
Physical prototypes also change the way designers think. Holding a mockup in your hands triggers a stream of ideas for improvement — insights that rarely emerge during sketching or 3D modeling. That’s why adopting a «fail fast» approach early on is crucial. Unlike software, physical products can’t be updated with a simple patch. Every key refinement must happen before production begins.
In this article, we’ll share our approach to prototyping at nao.design and the key stages of developing a new product.
We aim to create the best product within tight deadlines and budgets. Prototyping helps save time and uncover the best solutions. The first stage involves quick, low-fidelity mockups made from cardboard, foam, paper, and sometimes clay—simple materials that are easy to shape and modify. All you need is a knife, glue, and creative hands.
One of the most significant advantages of this approach is speed. You can test multiple ideas rapidly, iterate on different shapes, and identify the most promising direction early on. Designers often use foam, clay, or even plaster depending on the project's needs.
Clay mockups are particularly useful for designing components that will be handled frequently. They allow for precise refinement of ergonomic forms — something that’s hard to achieve with cardboard or foam alone.
Thanks to modern 3D printing, prototyping has become significantly faster and more accessible. Creating a functional mockup that closely mimicking a final product is now easier than ever.
At nao.design, we primarily use two types of 3D printing:
Depending on the project, we may produce anywhere from 10 to 100+ prototypes. A helpful tip: Print prototypes at a reduced scale when possible. This saves time, material, and cost.
After testing multiple printers, our go-to choice is the Bambu Lab Carbon X1—our undisputed favorite.
3D mockups allow us to test various design hypotheses: weight, physical characteristics, button feel, impact resistance, and more.
We follow an iterative process:
In some cases, we compare multiple versions side by side, testing how different design choices interact with PCBs and other internal components. We use SLS and SLA printing for glowing LED elements for better light diffusion.
SLA printers were once prohibitively expensive, but today, they’re more affordable and widely used in product development. This method provides extremely high precision, making it ideal for intricate parts.
However, it’s important to remember that 3D printing has its limitations:
The final prototyping stage is beauty mockups — high-quality models used for key presentations with executives or clients. These mockups come in two types:
Beauty mockups are used to test final CMF (Color, Material, Finish), weight, and tactile feel. You’ve probably seen these in stores — many phone and tablet manufacturers display non-functional beauty mockups to let customers experience the look and feel of different models.
Specialized factories produce these mockups to exact specifications, ensuring they closely match the final product.
Pro tip: Always factor in the final weight of your product, including how it's distributed. Weight plays a crucial role in user perception, and neglecting it during prototyping can lead to unpleasant surprises. Imagine designing a phone that feels perfect in prototype form — only to have it gain an unexpected 100g in production. This can drastically affect usability and customer satisfaction.
When designing physical products, rapid prototyping is one of the most valuable tools at your disposal. The more mockups you create early on, the more opportunities you have to refine your design, identify potential flaws, and make informed decisions before committing to production.
Advancements in 3D printing and other prototyping technologies have made this process faster, more accessible, and more cost-effective than ever. By combining traditional hands-on techniques with modern digital fabrication, designers can bridge the gap between concept and reality in a way that renders alone never could.
Beyond design validation, physical mockups also play a critical role in communication — both within teams and with clients. They foster collaboration, encourage user-centered thinking, and help align expectations across all stakeholders. Whether you're testing ergonomics, material finishes, or functional components, each prototype brings you closer to a successful final product.
As technology evolves, keeping up with new tools and methods will be essential for staying competitive. The best design teams don’t just follow trends; they experiment, iterate, and push boundaries. By embracing an iterative prototyping process, you can streamline development, reduce costly revisions, and ultimately create better products that truly meet user needs.
