TV prototype production is a critical link in the R&D of electronic consumer products, bridging the gap between design concepts and mass production. Unlike regular prototypes, TV prototypes must validate not only appearance and structure but also the compatibility of internal components (Par exemple, motherboards, screens) and user experience (Par exemple, bracket rotation, interface usability). This article breaks down the full production process, technologies clés, and material selections using comparisons, practical examples, and data, helping you create reliable TV prototypes for design verification and market testing.
1. Pré-production: Clarify Core Requirements
Before starting fabrication, define the prototype’s validation goals to avoid misalignment with R&D needs. TV prototypes typically focus on four key requirements:
| Catégorie d'exigence | Key Validation Goals | Real-World Application Example |
| Vérification de l'apparence | Confirm design elements like screen ratio (Par exemple, 16:9, 21:9), bezel width (Par exemple, 5mm ultra-narrow), material texture (Par exemple, metallic frame, matte back cover), et logo position. | A smart TV brand tests a prototype to ensure the 21:9 ultra-wide screen and 3mm bezel match the initial design—critical for marketing “slim design” claims. |
| Structural Validation | Test the stability of the base/stand, layout of trous de dissipation de chaleur, and assembly space for internal components (Par exemple, motherboards, alimentations). | An OLED TV prototype’s base is tested to support 15kg (the TV’s weight) without tipping over; heat dissipation holes are checked for proper alignment with the motherboard. |
| Validation fonctionnelle | Simulate real usage to test button feel, interface compatibility (Par exemple, HDMI, USB), et screen-body fit (Par exemple, no gaps between the screen and frame). | A prototype’s HDMI 2.1 port is tested with a gaming console to confirm stable 4K/120Hz signal transmission—avoiding post-launch user complaints about interface issues. |
| Validation du processus | Verify the feasibility of surface treatments (Par exemple, pulvérisation, électroplaste) and material selections (Par exemple, aluminum alloy for frames, plastic for back covers). | A manufacturer tests electroplating on a prototype’s metal frame to ensure uniform metallic luster—preventing batch inconsistencies in mass production. |
2. Design Stage: 3D Modélisation & Part Splitting
Use professional CAD software to create a precise digital model, focusing on TV-specific structural details and processability.
2.1 3D Modeling Key Rules
| Design Focus | Exigences & Conseils | Reason for Attention |
| Précision dimensionnelle | Strictly follow design drawings for critical dimensions: screen size (Par exemple, 55-pouce, 65-pouce), interface position (Par exemple, HDMI ports 20mm from the bottom edge), et bezel width (error ≤0.1mm). | A 55-inch TV prototype with a 0.2mm wider bezel may look “bulky” compared to the design—ruining the “ultra-slim” aesthetic. |
| Thin-Wall Treatment | TV frames and back covers are often thin (1-3 mm). For 3D printing/CNC machining, ajouter Structures de soutien (for SLA printing) or optimize cutting paths (pour CNC) pour éviter la déformation. | A 2mm-thick plastic back cover prototype, if printed without supports, may warp by 1.5mm—making it impossible to assemble with the frame. |
| Curved Screen Simulation | For curved TV prototypes, accurately model the screen curvature (Par exemple, R5000mm) and use transparent materials (Par exemple, acrylique, clear resin) to simulate glass screens. | A curved OLED TV prototype uses a transparent resin screen with R4500mm curvature to test how light reflects off the curved surface—critical for reducing user eye strain. |
2.2 Part Splitting Strategy
Split the TV into modular components for easier production and assembly:
- Main Components: Screen frame, back cover, base/stand, interface panel, and internal brackets.
- Splitting Principles:
- Separate parts with different materials (Par exemple, metal frame vs. plastic back cover) to simplify material selection.
- Reserve 0.1–0.2mm assembly gaps between parts (Par exemple, frame and back cover) to avoid tight fits during assembly.
- Split large parts (Par exemple, a 65-inch back cover) into smaller sections if using 3D printing (max print size limit: ~300mm for most FDM printers).
3. Prototype Fabrication: Choisissez la bonne technologie
Select fabrication methods based on your prototype’s purpose, taille de lot, et les besoins matériels. TV prototypes commonly use three core technologies:
| Fabrication Method | Scénarios applicables | Technologies clés & Matériels | Avantages | Désavantage |
| 3D Impression | Vérification de l'apparence, small-size components (Par exemple, télécommande, panneaux de bouton), preliminary structural testing. | – SLA/DLP: Haute précision (± 0,05 mm) pour des surfaces lisses (Par exemple, screen frames); matériels: résine photosensible (white/transparent).- SLS: Pour des structures complexes (Par exemple, articulated brackets); matériel: nylon (difficile, no supports needed). | Rapide (12–24 heures par pièce), low cost for single prototypes, Idéal pour les formes complexes. | Limited to plastic/resin; not suitable for large metal parts (Par exemple, socles). |
| Usinage CNC | Metal material verification, high-precision structural parts (Par exemple, aluminum alloy frames, trous de dissipation de chaleur), screw hole testing. | – Five-axis CNC: For curved or irregular parts (Par exemple, curved TV frames); matériels: alliage en aluminium, acier inoxydable, cuivre. | Précision ultra-élevée (± 0,05 mm), real metal texture, durable for repeated assembly tests. | Lent (3–5 days per part), high cost for small batches. |
| Replica Molding | Small-batch reproduction (Par exemple, 10–50 units for exhibitions, marketing samples), complex shape replication. | Use 3D-printed/CNC-machined parts as master molds; produce copies via silicone molds with materials like polyurethane or epoxy resin. | Low cost per unit, fast batch production, consistent quality across copies. | Requires a master mold (adds initial cost); not suitable for high-precision metal parts. |
Selection Guide Table: Match Method to Your Needs
| Scénario | Méthode recommandée | Exemple de matériel | Délai de mise en œuvre |
| Low-cost appearance test (1–2 units) | 3D Impression (Sla) | White photosensitive resin | 1–2 jours |
| Metal frame verification (5 unités) | Usinage CNC | Alliage en aluminium 6061 | 3–4 jours |
| Exhibition samples (20 unités) | Replica Molding | Polyuréthane | 2–3 jours |
4. Assemblée & Tests fonctionnels
Assemble components into a complete prototype and validate its performance against pre-defined requirements.
4.1 Processus d'assemblage
- Component Preparation: Clean parts to remove burrs or dust (Par exemple, sand the CNC-machined frame with 800-mesh sandpaper).
- Assemblage étape par étape:
- Attach the screen to the frame (use double-sided tape or screws for stability).
- Install internal brackets to fix the motherboard and power supply.
- Assemble the base/stand (ensure it locks securely with the TV body).
- Assembly Simulation: Follow the mass production assembly sequence to identify potential issues (Par exemple, “Is the motherboard easy to install without interfering with the power supply?»).
4.2 Key Functional Tests
| Type de test | Comment jouer | Pass/Fail Criteria |
| Test d'apparence | Check gap uniformity (between screen and frame: ≤0,1 mm), material texture consistency, and logo alignment. | No visible gaps, texture uniforme, logo centered within ±0.5mm. |
| Essai structurel | Test base load-bearing (apply 1.5x the TV’s weight for 24 heures), bracket rotation (Par exemple, 180° swivel for wall-mounted TVs), and heat dissipation hole ventilation (use a wind tunnel to measure airflow). | Base doesn’t deform; bracket rotates smoothly without jamming; airflow meets 5L/min (minimum for heat dissipation). |
| Interface Test | Plug in HDMI, USB, and power cables to verify fit (no loose connections) et fonction (Par exemple, USB port charges a phone, HDMI transmits video). | All interfaces fit securely; functions work without glitches. |
| Screen Simulation | Use an acrylic board (for appearance prototypes) or LED screen (Pour les prototypes fonctionnels) to test screen-body fit and light leakage (check for light seepage around the frame). | No light leakage; screen fits flush with the frame. |
5. Post-traitement & Optimisation
Refine the prototype’s appearance and functionality to meet design standards and fix common defects.
5.1 Options de traitement de surface
| Méthode de traitement | But | Exemple d'application |
| Peinture pulvérisée | Achieve color effects (Par exemple, noir mat, gradient color) or simulate materials (Par exemple, imitation metal). | A prototype’s back cover is sprayed with matte black paint to reduce fingerprint visibility—improving user experience. |
| Impression d'écran en soie | Add screen parameters (Par exemple, “4K UHD”), logos, or key identifiers (Par exemple, "Bouton d'alimentation"). | HDMI port labels are silk-screened on the interface panel to guide users—avoiding confusion with USB ports. |
| Électroplaste | Create a metallic finish (Par exemple, chrome, nickel) for metal frames or plastic parts. | A prototype’s aluminum alloy frame is electroplated with nickel to enhance corrosion resistance and metallic luster. |
5.2 Common Defect Fixes
| Défaut | Causes | Solutions |
| Frame Deformation | Thin-wall structure (1–2 mm) + improper CNC cutting paths; 3D printing without supports. | Optimize CNC cutting speed (reduce to 30mm/s); add SLA supports for thin parts; use stronger materials (Par exemple, aluminum alloy instead of plastic). |
| Interface Looseness | Incorrect hole diameter (Par exemple, USB port hole is 0.2mm too large); poor assembly alignment. | Adjust 3D model to reduce hole diameter by 0.1mm; use guide pins during assembly to ensure alignment. |
| Light Leakage | Gaps between the screen and frame; uneven screen installation. | Add foam gaskets between the screen and frame; use screws to secure the screen evenly (4–6 screws for a 55-inch TV). |
6. Key Notes for TV Prototype Production
To avoid costly rework and ensure prototype reliability, follow these critical guidelines:
- Précision dimensionnelle: Use calipers and coordinate measuring machines (Cmm) Pour vérifier les dimensions clés (Par exemple, screen size, interface position) with an error ≤0.1mm.
- Assembly Simulation: Plan internal component layouts (Par exemple, motherboard, battery 仓) in advance to avoid interference during mass production (Par exemple, “Does the power supply block the heat dissipation fan?»).
- Surface Treatment Consistency: For multi-batch prototypes (Par exemple, 10 exhibition samples), use the same paint batch and electroplating parameters to ensure uniform color and texture.
- Confidentiality: Sign a non-disclosure agreement (NDA) with the prototype manufacturer to protect unlaunched design details—critical for preventing design theft.
7. Yigu Technology’s Perspective on TV Prototype Production
À la technologie Yigu, we’ve found that TV prototype success depends on balancing “design fidelity” and “process feasibility.” Many clients initially prioritize ultra-thin bezels (Par exemple, 2MM) but overlook that 3D-printed prototypes may warp—we recommend starting with a 3mm bezel for the first prototype, then optimizing to 2mm after structural validation. Pour la sélection des matériaux, we often advise combining aluminum alloy (pour les cadres, via CNC) and SLA resin (for back covers, via 3D printing)—this balances durability and cost. Par exemple, a client designing a 65-inch QLED TV saved 30% on prototype costs by using this hybrid approach, while still validating both appearance and structure. TV prototypes are not just “models”—they’re tools to de-risk mass production, so attention to detail (Par exemple, 0.1mm gap control) est non négociable.
8. FAQ: Common Questions About TV Prototype Production
T1: Can I use 3D printing for the entire TV prototype (including the frame and base)?
A1: It depends on the prototype’s purpose. For appearance tests, 3D-printed resin can simulate the frame and base. But for structural tests (Par exemple, chargé de chargement), pièces métalliques (Par exemple, aluminum alloy base via CNC) are needed—3D-printed plastic lacks the strength to support the TV’s weight (10–20kg) sans rupture.
T2: How long does it take to produce a TV prototype?
A2: Lead time varies by method and complexity. A simple appearance prototype (55-pouce, 3D-printed SLA) prend 1 à 2 jours. A functional prototype with CNC-machined metal parts and assembly takes 3–5 days. Small-batch replica prototypes (20 unités) take 2–3 days after the master mold is ready.
T3: Why does my TV prototype have gaps between the screen and frame?
A3: Gaps are usually caused by two issues: (1) Incorrect 3D model dimensions (Par exemple, frame is 0.2mm smaller than the screen); (2) Uneven assembly (Par exemple, screws are tighter on one side). Correctifs: Adjust the 3D model to increase frame size by 0.1mm; use a torque wrench to tighten screws evenly (5–8 N·m for plastic frames).