Workaround for Prototype

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After speaking with my manufacturer, I think that we might have a new workaround to properly test and show the functionality of my prototype. This problem will be obviously fixed once the product is manufactured, it’s just a pain right now due to my time constraints.

In some ways, this issue has likely resulted in a better outcome. Because I was concerned about how hard it was to properly show the product working within a normal home, I’ve hired a carpenter to build a portable display so that I can demonstrate this product live at the launch, as well as for the video.

It seems like everything I touch these days requires me to draw something, and God didn’t give me that gift. I hope my carpenter understood.

Rough sketch of product display for carpenter
Another rough sketch

I also have a meeting this afternoon with a company that will edit my videos for the crowdfunding campaign, and it will be good to hear what they think of my revised storyboard idea.

This is just proving to me once again that a roadblock on this entrepreneurial journey might actually be a detour to a better route in the end!

First prototype tests failed

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It was an incredibly frustrating day as my first prototype tests failed. While I didn’t expect the prototype to be perfect, I did believe that any failure would be a fault in my specifications, not because it wasn’t made properly.

As mentioned last week, my new prototype won’t stay together because the connector piece is still failing off. I thought I solved it last night by putting painter’s tape around the pin to make it slightly larger, but it didn’t hold.

The only good thing about today is that I did learn some new things about what the customer needs. The product itself also showed all promise that it would solve the intended problems with their pet. Oh yes, I also got a lot of doggie love.

Robert the Dog as Prototype Tester
Prototype Tester – Robert the Dog

Nevertheless, I’m clearly going to have to come up with a different solution over the next few weeks to avoid another prototype test failure. I only have a little bit of time left to demonstrate it properly on video for the crowdfunding campaign.

What if my prototype fails?

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I had an “oh shit” moment yesterday when I suddenly thought, “What if my prototype fails?” In reality, that’s why you have a prototype – so that you can fully test it and make adjustments. However based on my schedule of events, I won’t have time to properly test the prototype before I need to make the video for the crowdfunding campaign (though it would be fully tested by the time we manufacturer the product itself).

Speaking with my manufacturer this week, it also looks like the company that’s making the prototype doesn’t have enough 3D printing feedstock in the same colour to do it right now. It will delay things by three weeks if I insist that all the panels are in the same colour of white/cream.

Mismatched 3D printer plastic feedstock for my prototype

We’re going to see if they can make it in a different type of plastic – PP #5 (like a detergent bottle) versus the originally ordered ABS #7 (like legos), and perhaps they might have enough in the same colour then. Apparently, this is not an issue even though we had actually planned to manufacturer in HDPE #2 (milk jugs) because of the additives that need to be used. If your confused, more info about the different types of plastics can be found here.

Regardless, we can’t afford any delays in receiving the prototype. So, I told my manufacturer that I accept the fact that we might have to paint the prototype if it arrives in mismatched colours. It’s just a last resort though.

I also told him that after the videotaping was over, we were going to take the prototype to his house to give it a good workout to make sure that it does pass all of the tests prior to making it. If the prototype fails, it better be then. I’m sure that too will be a good video.

Simplifying my brand strategy

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I decided to simplify my branding strategy. Rather than promoting each product’s brand individually, I will only promote the brand line itself. Otherwise I think it might get too confusing for the customer. Good thing I made this decision before all the design work was done on the products. I’m sure that I’ll find some other good use out of the logos I’ve already had designed.

Told Manufacturer #1 that I would be back in touch when I have all three draft designs done so that they can give me a proper quote on all three. Once contracts are signed, they need between 5-10 days to update/test the designs (apparently called the DFM process) and to produce a 3D print prototype. I need at least one prototype ready for a grant that I’ll apply for next month. It would be great to have all three.

When Start-up Costs are High

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I realise now why so few people go into manufacturing products – the start-up costs are huge! Service-based and information-based businesses can largely be started with little capital. Even my previous tea company only needed about $5k to get started before I had a batch of products to sell.

My ambitions to do something with recycled plastic this time is far more expensive than any business I’ve ever tried. Sure, I can buy something from China and private label it for minimum costs, but I wouldn’t be fulfilling the purpose of the social enterprise (to reduce plastics going to landfills and waterways by making great products out of Australian recycled plastic).

How much am I talking about? Well, the design and mould costs alone for my simplest product is estimated to cost $30k. This is before I even have one product to sell.

While 3-D printing has definitely revolutionised the cost of prototypes, the process itself is not ideal for mass production or even performance testing of products that must have some level of strength or rigour.

Therefore, in order to make more robust and mass produced items, moulds still have to be made in a material that is significantly stronger and can withstand greater heat than the product material itself i.e. plastic.

Having these costs upfront is useful as I can more accurately assess risks and cashflow. At the same time, I can’t afford to fund all these moulds myself with only the savings I put aside after selling my investment property.

I always think that roadblocks are God’s way of telling me to pivot or shift directions.

I’m going to have to rethink my funding model to make it happen. Maybe, I go ahead and pay for the full design and product prototypes and see if I can somehow pre-sale or crowdsource cash to pay for the moulds. I may also be able to afford one mould if I can get a local government grant in August to start this project. Having the prototypes ready will be useful to convince people that the idea is worthy.

Any advice from my readers?

-Tammy

First view of Product #2

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Saw first CAD design of Product #2. Looks amazing when compared to my horrible hand drawings. Provided feedback to my designer for some changes. Because I don’t know what the technical terms are for the various parts, I questioned the use of “toaster and bread” connection pieces versus the “hotdog and bun” connectors we had discussed earlier. I’m sure he’s laughing at me!

Also, provided design changes feedback for my extra product logos. They look great.

When your mock-up product destroys your house

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Shared my business idea with a good friend. He thought that it made a lot of sense for me personally and to fill an obvious need. It’s good to get that kind of confirmation from people that know me well.

Mocked up Product #3 with some random things that I thought might functionally operate in a similar way – it worked. But… DAMN IT! I have to fix my wall now. Better that I tested this is my house than a customer’s.

Product design mock-up failure!

Searching for manufacturers and parts

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Went to hardware store to see if there were any standard parts that I might be able to use for Product #1 or #2. Nope! And nothing like these products really exist there.

Put together a rough budget with no real idea about how much it’s going to cost to get these products manufactured. I heard that simple moulds could cost about $20k each. This is definitely going to be the most expensive business I have after started.

Found an Australian product designer/manufacturer online – Manufacturer #1. I liked what they had done for another business in their case studies – makes me think that our values are aligned. I need to put together some sort of product requirements doc for a prototype before I call them. I’m not really sure how to do that, but I suppose I can use a similar format that I would have used for software development in my old IT days

No go on local product designer

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Heard back from a local product designer – he’s busy for the next few months. Damn! There doesn’t appear to be many here in Canberra.

Do I learn a new skill like CAD?

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Prepared some market research questions so that I can survey people.

Also did some more research on 3D printing and CAD. I wish I had these skills. It would make my product design process so much easier. There doesn’t seem to be any classes locally unless I want to enter an actual degree program. It’s probably for the best that I don’t waste my time in learning this skill when I can hire experts that will always be better than me.