The cart before the horse October 16 2013
So I paid an engineer friend to do professional CAD drawings in order to start the prototype and quote request process. I originally envisioned the handle as all stainless steel, but I learned instantly that this approach would be way too expensive to manufacture. I wanted it to have a rounded handle to keep it compact, and I thought running metal into the handle would make it attractive and durable. So off I went! Prototypes came along nicely, and I quickly ordered ten with the intent of sending some out as samples to potential buyers. In theory this was perfect. In reality, I should have just started with one and could have saved myself about $3500 if I would have.
After receiving all of my prototypes and fine tuning my manufacturing quotes, I learned that the tolerance required to perfectly match up the steel and the handle would be almost impossible to maintain in manufacturing. That's right – my ten prototypes were expensive and totally useless. And back to the drawing board I went.
Lesson learned: Never order more than one prototype at a time unless you know – without a doubt – that you have a final design.