During the research stage we need to understand how the end user is engaging with the product, what sort of environment it is in and what it is being used for. This is human factors and usability research.
Next we want to understand the competitive landscape. What are their prices, features, benefits, reviews, patents, materials, manufacturing methods, etc.
This is the exploration stage, the top of the funnel where narrowing in isn’t an option.
Here, multiple design directions will be explored and visually explained with hand sketches and 2D renderings. Each design will have varying aesthetics, configurations, colors, materials and mechanisms that will be considered, researched and developed.
3D CAD MODELING
Once we have narrowed in on a design direction we begin modeling the concept in Solidworks, while always considering: part-line breakup, manufacturability, ease of tooling and assembly and other design for manufacturing guidelines.
Using the CAD files we create functional prototypes using various methods: 3D printing, CNCing, metal bending, welding, sewing, painting, urethane casting, etc. The prototypes are used to test the functionality of the product and to critique the size, shape and surface development. This allows us to catch any issues before we finalize the CAD for production.
Once we have a prototype that looks and functions correctly we create production specification sheets for every part that details out the: production method, material, surface finish, tolerances, pantones, cut lines and assembly details. These sheets, along with the CAD files, are everything needed for a factory to provide a tooling and per unit quote.
Some clients already have factories they use for production. Others don’t have the time to liaison the production and shipping process. We use our long term manufacturing, QC inspection and logistics partners to handle this for you so you can focus on product sales.