Prototype lab splicing is performed in low-volume, high-variability environments focused on design validation rather than production optimization. Splicing here serves primarily as a convenience mechanism rather than a continuity requirement.
Long-term adhesive degradation mechanisms remain dormant.
Prototype environments are characterized by:
Under these conditions:
Mechanical failure modes are therefore biased toward:
Prototype success is often mistakenly interpreted as proof of production readiness. However, the mechanical envelope of prototype operation represents only a narrow subset of production conditions.
Scaling from prototype to production introduces:
Engineering decisions based solely on prototype splicing outcomes fail to capture the dominant failure mechanisms present in volume manufacturing. Prototype validation must be supplemented with production-context stress modeling.
