How to make a cardboard prototype

Quick summary

Andrew Brace, a prototyper at Quirky, demonstrates building a cardboard prototype of an interactive toaster (a toaster with a touchscreen that burns user-drawn designs into toast). The demo shows how inexpensive materials can be used to explore size, scale, form, and function before moving to more advanced tools.

Materials

• Cardboard and paper
• Tape and glue
• Cutting tools (utility knife/scalpel)
• Later-stage tools available at Quirky (not used for the initial mockup): 3D printers, CNC machines

Process / workflow

1. Sketch the idea first to estimate size, shape, material needs, and approach to cutting/gluing.
2. Start with the simplest possible box model: cut six sides and tape them together to test basic form and proportions.
3. Make a first model to learn and identify changes.
4. Create a refined model using fewer pieces (fewer part breaks = cleaner look).
5. Iterate further or move to higher-fidelity techniques/tools as needed.

Techniques and creative solutions

• Scoring: cut just the surface of the cardboard (not all the way through) to create controlled bends and rounded edges.
• Layering/stacking: cut concentric circles that decrease in size and stack them to build a round knob in cardboard.
• Incremental cutting for curves: make several small cuts instead of trying to cut a smooth curve all at once.
• Use cheap, approachable materials to quickly externalize ideas so others can understand and give feedback.

Design and prototyping principles

• Use simple, low-cost prototypes to explore size, scale, and form rapidly.
• Iterate quickly: a rough model reveals needed refinements for later versions.
• Simplify parts where possible to make the model look more refined.
• The goal of prototyping is to communicate an idea clearly and enable informed decisions for refinement.

Creators / contributors

• Andrew Brace (prototyper)
• Quirky (company)