Shenzhen Alu Rapid Prototype Precision Co., Ltd.

The cost to build a prototype car varies significantly based on its purpose, complexity, and whether it’s a concept or production-intent prototype.

 Here’s a breakdown based on available insights:

1.Non-Functional Concept Car (Display Only): $100,000–$500,000. These are often static or minimally functional, built to showcase design or technology at auto shows. Costs include custom design, clay modeling, and high-quality materials, but no full powertrain or extensive engineering. For example, a full-sized concept car can cost upwards of $300,000, while scaled models may be under $100,000.

2.Functional Prototype (Production-Intent): $250,000–$1,000,000+. Early-stage prototypes for testing (e.g., mules or rolling chassis) can cost $250,000–$750,000, while later-stage, near-production prototypes range from $500,000–$1,000,000. Costs include custom parts (e.g., CNC-machined aluminum components, custom wiring harnesses costing 4–10x production parts), engineering salaries (a team of 10 engineers can exceed $1M/year), and testing (e.g., crash, thermal, or NVH tests). For instance, GM estimates early prototypes at $750,000 and later ones at $250,000, depending on shared components.

3.All-New Vehicle (New Platform, Powertrain): $10,000,000+. A fully custom vehicle, like an electric vehicle (EV) or a new platform, can cost significantly more due to bespoke engineering, unique tooling, and extensive R&D. A one-off automotive design model can cost around $10M if it’s entirely new without shared components.

Key Cost Drivers:Parts and Materials: Hand-built components (e.g., radiator brackets or suspension parts) are expensive due to lack of production tooling. Custom parts can be 4–10x the cost of mass-produced equivalents.

4.Labor and Engineering: A team of 10–1,000 engineers/designers at $150,000–$600,000/year each can lead to millions in salaries over a 1–4 year development cycle.

5.Testing and Facilities: Real-world tests (e.g., in extreme climates like Death Valley) and facility costs (e.g., retooling factories) add significant expenses.

6.Complexity and Novelty: Using off-the-shelf parts (e.g., engines from Continental or axles from Timken) reduces costs, while all-new designs skyrocket them.

7.Scale of Production: Prototypes are costly because they lack economies of scale; a single prototype absorbs all design and engineering costs.

8.Timeframe:Building a production-intent prototype typically takes 6–18 months, depending on complexity and existing infrastructure. Six months is feasible for a manufacturer with existing facilities but optimistic for a novel design.