Free template · Prototype test plan

Prototype test plan: 9 tests to run before you pay for tooling

One prototype that works on the bench proves very little. A test plan says what you will test, to which standard, on how many units, and what counts as a pass, before anyone builds anything. Use this plan to agree the tests with your engineers, then record every unit’s result.

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The 9 tests

Agree these with your engineers first

Testing one prototype proves almost nothing: plan enough units to see a pattern, and record each unit by serial number. The PDF turns this into a plan you fill in, with a result box for every unit.

Does it work, and survive handling?

3 items

01
Functional test against a real duty cycleFinds: Intermittent failures and drift over repeated cycles. Run radio bursts, motor starts and sleep cycles as in real use, at both ends of your temperature range. Pass: Every function meets its spec across the range.
02
Drop testFinds: Cracked housings, loose mounts and dislodged batteries. For example MIL-STD-810 Method 516, Procedure IV: 26 drops from 48 inches across five units. Pass: Still works, with no hazard.
03
Vibration and transitFinds: Loosening fasteners, fretting connectors and cracked solder joints. ASTM D4169 or ISTA random vibration profiles. Pass: No fatigue failures after the profile.

Will it survive the environment?

3 items

04
Cold and dry heatFinds: Brittle materials, failed seals and sensor drift. IEC 60068-2-1 and 60068-2-2. Powered products use Test Ad. Pass: Works at both extremes of your declared range.
05
Damp heatFinds: Corrosion and condensation faults. IEC 60068-2-78, at 85 to 93% relative humidity. Pass: Works after exposure, with no corrosion.
06
Water and dust (IP rating)Finds: Whether the IP claim on your box is true. IEC 60529, for example IPX4 splash or IPX7 at one metre for 30 minutes. Ratings do not stack. Pass: No harmful ingress for the claimed rating.

Can it be shipped, certified and used?

3 items

07
Battery transport (UN 38.3)Finds: Whether lithium cells can be air-shipped at all. Eight tests, including altitude, thermal cycling and vibration, at an accredited lab. Pass: A UN 38.3 test summary from the lab.
08
EMC pre-scanFinds: Radio-noise problems while the design can still change. A pre-scan against FCC Part 15 Class B limits before the accredited lab. Pass: A comfortable margin below the limits.
09
UsabilityFinds: The problems real people hit. Five users find most problems; claiming a success rate needs 30 or more. Pass: No task-blocking problems left.

Download the test plan (PDF)

Every test with its standard, units and pass rule, a result box for each of five units, and a sign-off before tooling.

Prototype testing checklist for inventors →Prototype vs MVP →Environmental requirements for hardware →

FAQ

Questions about testing a prototype

How do I test a hardware prototype?

Agree what you will test, to which standard, on how many units and what counts as a pass, before anyone builds anything. Then record every unit by serial number. The plan covers nine tests, from function and drop to heat, water, battery and EMC.

How many prototypes do I need to test?

More than one. One prototype that works on the bench proves very little; plan enough units to see a pattern. A drop test, for example, can run 26 drops across five units.