From Artifact to Decision Instrument: A Critical Review of Prototyping in Engineering Design

Prototyping has evolved from a simple representational artifact into a central mechanism for learning, communication, risk reduction, and decision-making in engineering design. Despite its widespread adoption across engineering disciplines, existing research remains fragmented across domains, methodologies, and application contexts, making it difficult to distinguish broadly applicable principles from context-specific practices. This paper presents a critical review of prototyping research in engineering design, synthesizing evidence from peer-reviewed journal articles and conference papers from foundational studies of the 1980s to recent developments in rapid prototyping, additive manufacturing, digital engineering, and Industry 4.0 systems. A thematic literature review was conducted to identify recurring principles, domain-dependent variations, emerging trends, and persistent limitations in current prototyping practices. The review examines key factors influencing prototyping effectiveness, including purpose, fidelity, timing, stakeholder involvement, modeling and analysis, risk management, economic considerations, and learning-oriented iteration. Particular attention is given to how uncertainty influences prototyping decisions and the ways in which different uncertainty conditions influence the selection, scope, and implementation of prototyping activities. The findings indicate that prototyping is best understood as a context-dependent decision-support activity whose effectiveness depends on the uncertainties, constraints, stakeholders, and design objectives associated with a specific engineering problem. Although several common principles emerge across engineering domains, substantial differences exist in how prototypes are used to support design decisions and system validation. The review identifies research gaps related to uncertainty-driven fidelity selection, integration of modeling, experimentation, and verification activities, and the limited availability of systematic guidance for selecting prototyping strategies across diverse engineering contexts. Future research should focus on generalized prototyping frameworks, quantitative decision-support methods for uncertainty management, enhanced stakeholder integration, and the continued convergence of physical and virtual prototyping environments in next-generation engineering systems.