Thanks for your help anyways.
funny as it sounds the manufacturing I have all figured out (or so I think) I have a list of the parts that I need to find factories that do those stuff after finding them all I am left with is someone for the assembling.
But creating a prototype I am just not getting it, how can I make just one or two pieces while keeping the costs down, no one is going to make me molds just for 2 Pcs. 3D Printing is also not an option as I need some real large parts.
To be fair, you should check your accountant. However, since expenses are pass-through losses and float to your K1 if you have no income you could put it off. Keep in mind that means you will not be able to claim the loses which could offset other taxes due (until you do your taxes then you could claim them). It is best to file. Should you choose not to file, the IRS does require 1099’s be sent for any USA entity above 500$ in any given fiscal year and possibly foreign entities as well, and may deny any expense that you did not do this for. weather you file or not make sure you pay the annual fees on your S corp.