Turn a digital concept
into a physical
object you can evaluate.
Carve Model creates physical product prototypes and mockups from CAD files, drawings, sketches, reference images, renderings, and generated concepts.
Our prototypes help product teams communicate form, evaluate proportion, review materials and finishes, demonstrate an idea, and prepare for further development or production.
Some decisions require a real object.
A rendering or digital model can present an idea, but a physical prototype allows people to hold it, view it at its intended size, examine it from every angle, and understand how its components relate.
Depending on the project, a prototype can help teams:
- Evaluate overall form and proportion
- Review ergonomics and handling
- Compare materials, colors, and finishes
- Communicate a concept to stakeholders or investors
- Study components, joints, and assembly
- Demonstrate a product at an event or presentation
- Identify questions before committing to production
- Create a physical reference for further development
Built around what needs to be evaluated.
Appearance & Form Prototypes
Models developed to evaluate a product’s form, proportion, color, materials, finishes, and overall visual character.
Ergonomic & Interaction Prototypes
Models used to evaluate physical size, handling, comfort, reach, control placement, and how the product interacts with its user.
Functional & Assembly Prototypes
Prototypes developed to evaluate selected movements, mechanisms, component fit, connections, removable parts, and assembly sequences.
Define what the prototype must prove.
A single prototype does not always need to reproduce appearance, materials, assembly, and function at the same time.
Before production, we establish:
- What must look like the proposed product
- What must match the intended dimensions
- What needs to move or function
- What can be simplified
- Which materials or finishes require confirmation
- How the prototype will be handled or demonstrated
- Whether components need to be removable
- What remains outside the prototype's intended purpose
This prevents unnecessary complexity and focuses the scope on the decisions the prototype must support.
From reference image to fabrication-ready geometry.
We can review:
* When usable geometry exists, we prepare it for fabrication. When the project begins only with visual references or incomplete information, Digital Model Development may be separately scoped.
The developed geometry and interpreted design decisions are reviewed before physical fabrication.
Selected for the required outcome.
Depending on the project, production may combine:
- 3D printing
- CNC machining
- Laser cutting
- Acrylic, ABS, resin, wood, metal, or foam
- Painting and custom finishes
- Transparent or illuminated components
- Mechanical connections
- Removable or interchangeable parts
- Electronics and selected functional elements
- Skilled assembly and hand finishing
Materials and methods are selected according to the prototype's purpose, appearance, accuracy, handling, schedule, and budget.
A prototype has a defined purpose.
A product mockup or prototype does not automatically certify manufacturing readiness, engineering performance, code compliance, safety, or durability.
Where those forms of validation are required, the appropriate engineering, testing, certification, or production specialists should also be involved.
Carve defines clearly what the prototype is intended to communicate or evaluate.
From concept to physical evidence.
Define the audience and evaluation objective
Confirm dimensions, functions, materials, and constraints
Review or develop the required digital geometry
Produce samples or partial mockups when useful
Approve key design decisions
Fabricate, assemble, finish, and test the defined features
Package and deliver the completed prototype
Common product prototype questions.
Can you create a prototype if we do not have a finished 3D model?
Yes. We can begin with sketches, drawings, photographs, renderings, AI-generated images, reference products, or partially developed CAD files. If fabrication-ready geometry does not exist, we will identify the additional information and separately scoped digital model development required before physical production.
What is the difference between an appearance prototype and a functional prototype?
An appearance prototype is primarily built to evaluate or present form, proportion, color, material, and finish. A functional prototype is developed to test specific physical requirements such as assembly, connections, movement, fit, access, or fabrication feasibility. A prototype may combine both purposes when clearly defined at the beginning of the project.
What materials and fabrication methods can you use?
Materials and production methods are selected according to what the prototype must demonstrate. Depending on the project, we may use ABS, resin, acrylic, wood, metal, foam, printed components, custom finishes, CNC machining, laser cutting, 3D printing, painting, and hand assembly. Material recommendations are made after reviewing the intended use, appearance, handling, and performance requirements.
How are product prototype pricing and schedules determined?
Pricing and lead time depend on the prototype's dimensions, geometry, function, materials, finish quality, number of components, source information, testing requirements, quantity, and deadline. After reviewing the available files and intended purpose, we provide a preliminary estimate and identify any design development required before fabrication.
Start a product prototype project.
Tell us what you are developing, what needs to be evaluated or demonstrated, and what information is currently available. We will recommend an appropriate prototype scope and production approach.