Prototype failures teach what production must not repeat.

Year

2026

Client

BrahmWorks Insights

Mechanical

Indoor kitchen planter with fresh herbs under an overhead grow light on a countertop

The Challenge

The same few, under different skins. A fit tuned on one printed unit.

A failure is useful only when you can say what it is evidence of. A crack in a printed polymer is weak evidence about a moulded boss in another resin.

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Prototype Failures

What we did

Mechanical

Industry

Mechanical

Description

This Insights guide explains Prototype Failures for founders and engineering teams building hardware that must be manufactured, tested, and handed off. A failure is useful only when you can say what it is evidence of. A crack in a printed polymer is weak evidence about a moulded boss in another resin. It also covers a fit that was adjusted on one unit; snaps, bosses and screws used as structure; hinges, seals and the material you did not test.

Three EV charger design concepts side by side with vehicle reference images

BrahmEarth assembly components on a workbench.

Round handheld device prototype packed in a moulded pulp tray

The Outcome

The failed feature is measured, not only photographed. The material, the process and the revision are on the note. Any hand filing or selected part is written, or the unit is discarded as evidence.