Prototyping perspex brooches

Prototyping perspex brooches

Rosemary wanted to design a range of perspex brooches, but she needed to find someone to help her laser cut them. This is our journey together to create her first new product and the role that prototypes played in perfecting the design.

All prototyping starts with the artwork

There are two things to decide at the beginning of a laser cutting project. Artwork is a very important element to get right, so I pointed Rosemary to Artwork website page and my blog about designing artwork for laser cutting. These pages summarise what I would need to cut her products. Rosemary knew she wanted to work with perspex and I suggested that 3mm was robust enough.

Within a couple of weeks, Rosemary was in touch with her Frankie Frog design.

Initial design

Frankie Frog was in two layers. There was a yellow base layer with an external cut out shape and an engraved eye that Rose wanted fill in engraved, and a green top layer. The external shape matched the yellow layer, but there were three cut out body panels to show the yellow underneath. An eye was cut out and there were some lines to vector engrave showing leg and back outlines.

As a reality check, I found some leftover green and yellow perspex and cut one of each shape. It was a promising start, but seeing the shapes in my hand showed flagged up some areas for improvement.

Frankie’s toes were quite thin and I worried that even when the two layers of the brooches were glued together, they could break easily. Also, the cut out areas in the green later for the nose, throat and tummy left thin edge strips that weren’t very strong. The engraved eye didn’t show up well on the yellow, and the engraved lines on the green were so close to the cut outs that they got lost.

At the top of the post you can see the first prototype on the left.

Dolly Dimple Designs
Frankie Frog from initial sketch to final product

Second brooch prototype

I recommendations to Rose were that the following actions could improve the product.

  1. the toes should be made sturdier and more robust
  2. the cut out panels could be moved away from the body outline to make the narrow strips thicker
  3. the cut out panels should also be reshaped to move them away from the vector engraved lines for definition
  4. move the nose further away from the edge
  5. the yellow eye detail should be cut out instead of engraved

When she saw the picture of the first prototype, she agreed, made some changes and sent new files. You can see the second prototype on the right in the picture at the top. The changes worked and we had a final design after only two iterations. Very efficient!

When the perspex arrived, I made Rose’s first order. Within a few weeks, I had helped Rose take her initial designs through to a new product that she was really happy with.

Dolly Dimple’s new Etsy shop

Rose assembled her frog pieces and finished everything to her liking. Now Frankie Frog is up for sale in her shiny new Etsy shop and she’s working away on some new designs!


Have you got a product you’d like to develop but aren’t sure how? Contact us or ask for a quote.