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Prototyping and Pre-Tooling for Toys
We turn your ID/ME outputs into functional and final prototypes. Wherever sensible we use off-the-shelf components to limit new tooling and cost. Surfaces are adjusted so graphics and paint land cleanly, and we define the initial manufacturing processes (later refined in DFM). Electronics are optional and integrated only when needed. Prototypes are often 3D-printed and therefore fragile-we package and ship them with extreme care. The sprint ends with a pre-tooling plan and an accurate tooling quote aligned to product complexity.
Note on EVT: in toys, electronics are usually simple. We keep any engineering validation checks light and only where they truly de-risk tooling.
What this phase achieves
Prototypes you can evaluate
New IP or play pattern that needs a clear build path and guardrails.
Graphics & paint ready
Flattened/smoothed surfaces, masking strategy, and process notes for spraying, UV printing, pad print or tampo.
Tooling plan & quote
Part splits, best process picks, Off-The-Shelf substitutions, and an accurate tooling quotation.
Your deliverable
A concise document that captures what we are building and the constraints it must meet-used by design, engineering, sourcing, testing and production.
What we'll do
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Prototype plan
(SLA/SLS/CNC/vac-cast/soft tooling) -
Functional prototypes (mechanisms, fits, fasteners)
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Final prototypes (surface finish & CMF cues)
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OTS parts first: motors, screws, bearings, LEDs, seals, gearsets when applicable
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Surface flattening & graphics/paint planning (masks & color breaks)
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Optional electronics bring-up (simple L/S/RC), battery door fit
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Light pre-checks: small-parts cylinder, battery-door torque, magnet retention (if used)
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Pre-tooling package: splits, process map, early mold count & tooling quote
What you'll provide
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Color/finish targets and graphic intent
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Play targets (runtime, strength, sound) if relevant
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Decision makers & review cadence; ship-to address for samples
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Any preferred vendors/factories to loop in
What you'll get (Prototype Pack v1.0)
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Photo set & short clips of assembly and key tests
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Prototype (s): works-like and/or final (marked fragile)
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Graphics/paint notes: masks, color breaks, texture callouts
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Pre-tooling plan: proposed splits & process selection
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Accurate tooling quotation + next steps to DFM & Tooling
Prototyping aiming at production
Functional prototypes of RC cars being assembled in a Chinese workshop.
Extreme cautious is necessary when packing prototypes for international shipping.
Plush toys also need special care when being prototyped.
Process & timeline (2-6 weeks)
⚠️ Reference only: timing varies with complexity, decision speed, and supplier calendars.
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Fast example: simple white ABS 3D print in 3-7 days (no electronics).
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Complex example: fully printed functional RC toy in 2-4 weeks minimum.
1
Week 1-2
Prototype plan - OTS parts ordering • Functional build & first reviews.
2
Weeks 2-3
Surface refinements - Graphics/paint tests • Final prototype.
3
Weeks 3-6
Additional rounds as needed (1-3 wks each): fixes - retests • quote updates.
4
Pre-Tooling
Splits & processes agreed • Tooling plan & accurate quotation.
FAQs
Do we need electronics in this phase?
How many prototype rounds are typical?
Will prototypes survive play-testing?
Can you lower tooling cost?
What prototype processes do you use?
Can you ship prototypes internationally?
Do you test safety aspects now?