002 the harsh reality of scaling your product from prototype to production.

✅ Cheat sheet: 👉 https://shorturl.at/5qSGX
rebeleng.us - Your top location for product design and development resources.

 If your prototype worked perfectly on your desk, that’s exactly why it might fail in mass production. In this video, I explain why prototypes lie, and how manufacturing exposes every shortcut you took. We cover the biggest mistakes first-time physical product founders make when moving from prototype to production, including tolerance stackup, material changes, 3D printing vs injection molding, tooling costs, assembly errors, and production speed. A prototype proves an idea. Mass production proves discipline. If you're bringing a physical product to market, this will help you avoid costly rework, blown tooling budgets, and painful manufacturing delays.

⏱️⏱️VIDEO CHAPTERS⏱️⏱️

0:00 – Why Prototypes Fail in Mass Production
0:52 – The Prototype Confidence Trap
1:12 – Proof of Concept vs Production Reality
2:03 – Variation, Tolerances & Why Parts Stop Fitting
2:29 – 3D Printing vs Injection Molding Problems
3:25 – Assembly Errors in High-Volume Manufacturing
4:19 – Tolerance Stackup & Six Sigma Explained
4:44 – Material Changes That Break Working Designs
6:54 – Tooling Costs, Undercuts & Manufacturing Risk
10:55 – The Mindset Shift: Design for Learning, Not Completion