Prototype to Production for Ceramic Components

What actually changes between the first part and a production order, and where continuity is usually lost between batch one and batch two.

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Ceramic forming presses on the workshop floor — Forming presses, the first step before any material is fired.

Stages

The three stages and what each proves

A prototype is one part made to prove the design works, a pilot batch is a small run made to prove the process is stable, and production is the repeat order where the process has to prove it repeats. A prototype is quoted separately from production because the route and the fixturing differ at that stage, and its typical lead time is 7 to 10 working days after drawing approval. The drawing is reviewed before any price is issued, so what is achievable is settled before production begins, and a change made at drawing review is absorbed into the quotation rather than charged as a new approval cycle.

1PrototypeOne part, made to prove the design works.
2Pilot batchA small run, made to prove the process is stable.
3ProductionThe repeat order, where the process has to prove it repeats.

Lead times run from drawing approval rather than from enquiry: 7 to 10 working days for a prototype, 2 to 3 weeks for a pilot batch, 4 to 6 weeks for production, depending on quantity and material.

Stage objectives and lead times
Stage	What it proves	Typical lead time
Prototype	The design works	7 to 10 working days after drawing approval
Pilot batch	The process is stable	2 to 3 weeks
Production	The process repeats	4 to 6 weeks, depending on quantity and material

LEAD TIMETypical lead time: 7-10 working days for prototypes, 2-3 weeks for small batches, 4-6 weeks for mass production. Final delivery date is subject to order confirmation.

Where batches diverge

Ceramic parts rarely fail because one part is wrong. They fail because batch two is subtly different from batch one.

Material grade and, where relevant, the supplier lot
Grinding sequence and fixturing concept
Datum scheme and inspection method
Process parameters recorded at first article
Change control before any adjustment is made

The cost of a late change

When a change is made and what it costs
Change point	Consequence
At drawing review	Absorbed into the quotation
After first article	New approval cycle and inspection
During production	Partially completed work is affected
At incoming inspection	Most expensive; already shipped

What carries across the stages

ENGINEERING NOTEThe first article record is what makes batch two verifiable. Without a retained record, continuity depends on memory rather than on evidence.

Where the work is done

CNC machining centres used for ceramic parts — Machining centres as they are run for ceramic work.

Surface grinding machine in operation — Surface grinding, where most of the flatness tolerance is made.

Frequently asked

Yes. Prototype quantity of one is available and is quoted separately from production because the route and fixturing differ.

Typical lead time: 7-10 working days for prototypes, 2-3 weeks for small batches, 4-6 weeks for mass production. Final delivery date is subject to order confirmation. A written date is issued with every quotation.

Yes, when requested on the purchase order, so it is planned into the inspection stage.

Send the finding with the drawing revision. Design changes are normal before production and far cheaper at that point.

Have a drawing that this guide applies to?

Send it with the material and the quantities. The review confirms what is achievable before any price is issued.

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