Dimensional Prototypes
Parts produced to verify packaging, clearances, mounting points and vehicle installation interfaces.
ENGINEERING · PROTOTYPING · MANUFACTURING
Prototype Part Production
Engineering-driven prototype production for vehicle components, door mechanisms, assemblies and new product development.
PROTOTYPE DEVELOPMENT
A prototype must answer a specific engineering question
Prototype production is not simply the manufacture of one component. The prototype should verify geometry, installation, movement, strength, assembly, production feasibility or another clearly defined technical objective.
TLG SYSTEMS supports the development and production of functional prototype parts and assemblies for vehicle systems, door mechanisms, special vehicles and customer-specific mechanical projects.
01
Build to learn before building to produce
Early physical verification can identify interface, tolerance and manufacturing problems before tooling or repeat production begins.
PROTOTYPE TYPES
Prototype production according to the validation objective
The required manufacturing method, material and level of detail are selected according to what the prototype must demonstrate.
Functional Prototypes
Components and mechanisms produced for movement, load, adjustment and operational assessment.
Assembly Prototypes
Multi-part assemblies used to verify component positions, fastening, access and assembly sequence.
Vehicle Installation Parts
Prototype brackets, supports and interfaces for physical installation on the vehicle.
Pre-Series Components
Initial parts produced using intended materials and processes before repeat production begins.
Replacement Prototypes
Prototype reproduction of existing, discontinued or difficult-to-source mechanical components.
PRODUCTION METHODS
Manufacturing routes selected for the prototype requirement
Prototype parts may combine several processes depending on geometry, material, function and required delivery condition.
01
CNC turning for shafts, pins, bushes and rotational parts
02
CNC milling for brackets, arms, blocks and custom geometries
03
Laser cutting and bending for sheet-metal components
04
Welding for frames, brackets and multi-part assemblies
05
Engineering plastics for guides, bushes and interface parts
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Additive manufacturing where suitable for the intended validation
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Surface and heat treatments according to functional requirements
VALIDATION OBJECTIVES
Engineering questions supported by physical prototypes
01
Packaging
Does the component fit within the available vehicle space and installation envelope?
02
Movement
Do the mechanism, linkage and adjacent components move without interference?
03
Assembly
Can the part be installed, adjusted, fastened and serviced as intended?
04
Manufacturability
Can the component be produced consistently using the intended manufacturing processes?
05
Functional Performance
Does the component perform the intended mechanical function under the defined conditions?
06
Design Improvement
What changes are required before final design release or repeat production?
PROJECT INPUTS
Prototype development can begin from different technical inputs
Available project information is reviewed to define the fastest and most appropriate route to a useful physical prototype.
Technical Drawing
Dimensions, materials, tolerances and component requirements
3D CAD Data
Component geometry, assembly position and interface information
Physical Sample
Existing component for measurement and functional review
Vehicle Measurements
Installation space, mounting points and surrounding interfaces
Engineering Concept
Functional requirement requiring design and prototype development
DEVELOPMENT LOOP
Prototype, review, improve and verify
01
Initial Design Review
Geometry, interfaces, materials and prototype objectives are reviewed before production.
02
Physical Verification
The produced part is assessed according to the defined dimensional or functional objective.
03
Engineering Feedback
Installation findings, production observations and required changes are recorded.
04
Design Revision
Agreed improvements are incorporated into the technical definition before the next stage.
PROTOTYPE WORKFLOW
From engineering requirement to physical validation
01
Objective Definition
The engineering question, component scope and required validation level are defined.
02
Technical Preparation
Geometry, materials, production method and inspection points are confirmed.
03
Prototype Production
The component or assembly is manufactured according to the agreed technical definition.
04
Review and Revision
Findings are evaluated and required design or production changes are identified.
APPLICATION AREAS
Prototype production for mobility and industrial projects
Door Systems
Vehicle Mechanisms
Mounting Brackets
Structural Components
Special-Purpose Vehicles
Rail Vehicle Components
Mechanical Assemblies
Vehicle Installation Interfaces
Replacement Parts
Pre-Series Components
Prototype limitations
A prototype does not automatically represent a production-approved, validated or certified component. Prototype material, process, inspection and testing requirements are defined according to the agreed project objective. Final design release, validation and approval remain the responsibility of the manufacturer and relevant project stakeholders.
START PROTOTYPE DEVELOPMENT
SEND PROTOTYPE DATA
Send your drawing, 3D data, sample or engineering requirement
Include the prototype objective, required quantity, material, application and target delivery schedule for an initial review.