The direct answer
Prototype a new product by identifying the largest unknown, building the cheapest test that can resolve it, and iterating from rough proof of concept toward a manufacturable design. Each version should answer a specific question.
Key points covered
- Test the riskiest assumption before polishing the design.
- Choose prototype methods based on the question being answered.
- Expect multiple iterations before manufacturing readiness.
Experience behind the lesson
I’m Charles McNall, an engineer, inventor, and exited founder with 18+ years in medical devices, automation, robotics, manufacturing, and physical-product startups. I co-founded Chuck Rack, led product development and commercialization, reached $250,000 in first-year sales, and completed a founder exit in 2024.
Full video transcript
Transcript: How Should a Founder Prototype a New Physical Product?
This is the complete timestamped transcript generated from the video captions. It has been formatted for readability but not rewritten. Automated captions can contain transcription errors; use the embedded video as the authoritative source.
[0:00] hey and welcome to the latest episode of
[0:03] startup Chuck today we're going to talk
[0:05] about
[0:07] prototyping basically how do you make
[0:10] the idea or product in your head if it
[0:12] isn't already something that you could
[0:14] just buy off the shelf that is so uh
[0:18] with that in mind let's first talk about
[0:20] our sponsor our sponsor today is Chuck
[0:24] rack manufacturers of the Chuck bucket
[0:28] and uh it's great cuz we're actually
[0:31] going to talk a little bit about
[0:32] prototyping of this as well it's a hitch
[0:35] Mount ski rack that fits on the back of
[0:37] your car also takes
[0:39] bikes but that in mind let's initially
[0:43] start with
[0:46] um what what do you do when you want to
[0:49] make a prototype of course everybody
[0:51] wants it to look like the final product
[0:52] at some point right
[0:55] but that's unlikely at the beginning so
[0:59] the right mindset set is to think about
[1:03] at least I like to think about my
[1:05] favorite subreddit or one of them which
[1:07] is uh shitty robots and so shitty robots
[1:12] is a subreddit where people go and
[1:17] make basically prototypes of different
[1:21] projects and it is just things duct tape
[1:24] to things to make them
[1:26] work uh here's a pencil sharpening robot
[1:30] right nothing super
[1:32] fancy um but everything you see right
[1:36] duct tape hot glue nothing special to
[1:40] make something work and
[1:43] uh you don't Legos great
[1:47] example so you don't need a lot in order
[1:50] for you
[1:52] to like make your prototype work you
[1:54] don't have to have a machine shop
[1:57] necessarily and you can get away with
[1:59] with a lot so for example for the Chuck
[2:02] bucket I had five six prototypes prior
[2:07] to getting it to the market and so the
[2:11] first one was a 5 gallon Home Depot
[2:14] bucket strapped to a bike rack on the
[2:16] back of the car and then the next
[2:19] prototype was this plastic bucket put on
[2:23] the back of a car with if you could see
[2:26] it's got a section where you can slide
[2:28] the bucket into and it was meant to be
[2:31] easily
[2:32] replaceable uh because plastic wasn't
[2:34] going to last in the winter right
[2:37] so of course that wasn't the final
[2:40] version I had So eventually I went to
[2:43] what I like uh my
[2:46] favorite website for uh laser cutting
[2:50] well first I designed it up in CAD
[2:53] where's laser cutting site there we go
[2:55] Ash cut ash cut is a laser cutting and
[2:59] sheet metal bending house and
[3:03] so I went into solid works and this
[3:06] isn't the bucket this is going to be
[3:10] my uh banana boober that I had worked on
[3:13] but you know essentially you design up
[3:17] your
[3:17] part and then from there you make a
[3:21] drawing and then you send it to a shop
[3:23] if you need to a 3D print house for
[3:26] example uh you could do that if you
[3:28] don't have your own 3D print house um
[3:32] material I like would be uh typically
[3:35] laser centered nylon is usually really
[3:38] cheap and strong and there's a whole
[3:40] bunch of online quick turn 3D printing
[3:43] shops but it's actually really cheap to
[3:46] get your own 3D printers for
[3:49] example you go into
[3:52] Amazon and all these printers are
[3:55] between $400 $1 and $400
[4:00] uh even if you want to get into resin
[4:01] ones which have much higher resolution
[4:03] but aren't as durable of a part you're
[4:06] looking at
[4:07] $500 um to get into that and these will
[4:10] all make small parts and even if you
[4:13] want to do circuit boards you can get
[4:16] custom circuit boards designed cheap if
[4:19] what you're trying to do is software um
[4:22] software is essentially you know fairly
[4:25] inexpensive because it's mainly your
[4:27] time I
[4:30] for example programmed an app uh for
[4:33] Android and it was terrible I mean it
[4:36] was just spaghetti code but that's kind
[4:38] of it if you care enough about what
[4:41] you're trying to make then you will find
[4:44] a way to make it assuming that the
[4:46] technical challenge you know isn't too
[4:48] hard again you're not going to make a
[4:51] time machine
[4:52] because technical challenges are
[4:54] extremely difficult there right but you
[4:58] could probably make a toaster that burns
[5:02] images into the toast with a laser or
[5:04] something like that that wouldn't be
[5:06] incredibly outside of the range of
[5:08] somebody having to learn the skills
[5:11] necessary to do that or find someone
[5:12] with the skills so the first thing I'd
[5:16] say is you have to be committed to
[5:19] putting in the effort to try and do it
[5:21] yourself or finding people who can help
[5:23] you do it so let's say you have an idea
[5:27] but you're not an engineer
[5:30] well you could probably find an engineer
[5:33] or find somebody else who is very
[5:35] interested in that idea shares the same
[5:38] interest as you thinks it will be
[5:40] successful and will put the time in and
[5:44] then you guys can split equity in some
[5:46] way or
[5:47] another if you can't convince anybody
[5:50] that uh has the skills you need to work
[5:53] on your project then chances are maybe
[5:55] the product isn't going to be great um
[6:01] it's a good way to weed out whether or
[6:03] not what you're trying to produce and
[6:05] sell is going to become a good product a
[6:09] lot of people get caught up with wanting
[6:12] all the equity not wanting to share it
[6:15] and I'll just say you
[6:18] can you can own a little bit of a big
[6:21] company or you can own a lot of a
[6:23] failure of a company by not ever having
[6:25] anything actually made so sharing Equity
[6:28] is not a bad thing especially if it gets
[6:31] your prototype made uh especially if it
[6:35] gets your product sold so sharing it
[6:38] with salespeople instead but we'll get
[6:40] into all that sort of other stuff in a
[6:42] different episode in terms of building a
[6:44] team but in terms of just getting your
[6:47] prototype made you also have other
[6:49] options out there so um if you're doing
[6:51] coding AI is great chat upt is actually
[6:55] really good um here's an example of you
[6:58] could write some bad code and it
[7:02] basically will talk you through the
[7:05] different parts of it um you can have it
[7:08] rough out code for you say I want some
[7:13] code that is in uh Java that will do a
[7:20] loop where it indexes between one and 10
[7:24] and then it'll spit all those things out
[7:25] and then you can basically keep using
[7:27] that and learn from it really save you a
[7:30] ton of time um another big thing you
[7:34] could do is college students and college
[7:37] students are a great resource I actually
[7:39] have two college students that do my
[7:41] marketing and uh roughing out oh not
[7:46] even roughing out they made the website
[7:48] great they did photo shoots and you
[7:50] might say was that prototyping well it
[7:53] is if you're trying to develop anything
[7:56] right
[7:57] so any aspect of your company that needs
[8:00] to get done if you're trying to get it
[8:02] done and it's not a final version then
[8:04] it's basically a prototype so college
[8:07] students are great they're cheap they're
[8:08] trying to build portfolios for working
[8:11] at a better company Long Term and
[8:14] chances are you can probably interest
[8:15] one of those to help you out uh in
[8:18] between their classes and whatnot if you
[8:21] don't know how to find college students
[8:23] and don't want to just be a weird person
[8:25] on a campus you can go talk to
[8:27] professors and they might be able to
[8:29] help you as well in terms of pointing
[8:31] out which students they think are good
[8:33] in their studies and might be able to
[8:34] help you with that but usually a friends
[8:36] and family network is is helpful as well
[8:40] uh another Last Resort for trying to get
[8:43] prototypes done especially in fields
[8:45] that you aren't necessarily good at is a
[8:48] website called Fiverr and Fiverr is
[8:51] great because let's say you need
[8:53] somebody to help you with PCB layout for
[8:55] a circuit board you can go on there and
[8:57] find somebody who probably get you a
[9:00] basic design of what you're looking at
[9:03] for less than
[9:05] $300 now now you look at this and you
[9:07] say okay these
[9:09] say $30 right or $90 well as you go
[9:14] through Fiverr you're going to realize
[9:16] like oh it's kind of a tiered system so
[9:18] they might draw a basic schematic up for
[9:22] $30 or if you need them to do
[9:24] prototyping it's going to cost a bit
[9:26] more right like oh I need someone to do
[9:29] this or that but in general they're
[9:30] usually willing to work cheap they
[9:33] usually have a fair amount of people who
[9:36] have rated them so you know whether or
[9:38] not they're going to do the job or not
[9:39] you can see previous work they've done
[9:43] and it's a great way to at least get
[9:45] started with
[9:47] it um let's see here so sewing textiles
[9:53] things like that if you want to get into
[9:56] textiles and you don't know how to sew
[9:58] you can hot glue Fabrics together tape
[10:00] them together super glue it doesn't have
[10:04] to be perfect yet and then once you get
[10:06] something that you kind of like using
[10:08] glue and the fabric and scissors and
[10:10] whatnot then you can go to uh fabric
[10:14] Cutters and and seamstresses and things
[10:17] like that and have them prototype up the
[10:20] uh Fabric and um clothing for you or a
[10:23] backpack or whatever you're working on
[10:26] so that's I mean kind of it for
[10:28] Prototype typing there is CAD out there
[10:31] you can learn for 3D modeling there's
[10:34] freead there is paid software like solid
[10:38] works uh solid
[10:40] Edge uh but there is also
[10:44] um another site the Name Escapes me
[10:47] right now which has free online CAD
[10:55] software it's called on shape and
[10:58] basically on shape is great because it's
[11:03] free uh as long as you don't mind it
[11:06] being
[11:06] public and so again chances are nobody's
[11:10] probably trying to steal your stuff but
[11:11] at least you can learn in on
[11:13] shape
[11:15] and figure out how to make things and
[11:17] then decide if doing a paid tier is
[11:20] worth it but for a lot of prototypes
[11:22] that you may be doing if you name them
[11:24] something arbitrary chances are nobody
[11:26] will ever actually find what you're
[11:27] working on and so then it doesn't really
[11:29] matter too much so on shape's a great
[11:32] one and then I had mentioned uh solid
[11:34] Edge if you join EAA which is the
[11:39] Experimental Aircraft Association of
[11:42] America you can get a student version of
[11:45] solid Edge for free which is also really
[11:49] good but uh freead and SketchUp and all
[11:53] those other things are other options for
[11:55] making 3D models but I'm not super
[11:57] familiar with those you'd have to go
[11:59] figure them out on your own so that's
[12:01] all I've got for learning how to
[12:04] prototype there's not a lot really other
[12:07] than just get your hands dirty and start
[12:09] making things or try and find some
[12:12] people who are willing to join your
[12:13] adventure so if you thought this episode
[12:17] was good please like And subscribe and
[12:19] if not then I will see you all
[12:22] later