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Design & Development

We can take your project from any stage to any further stage as you wish. We don't need CAD prints, final designs or the like, we can work from just an idea or sketch.

The very first step of any project must be to correctly research the market, competitors, costs, trends and business case. This research is fundamental to developing accurate and reliable targets with which to start developing concepts around, and to create a business finance plan. This is also the time to research and develop benchmarks for the proposed idea in order to hit the target market at the correct level.

Part of the research is to identify a budget and master schedule for the project. The budget has to be based on fact and data, and the schedule is critical. Non adherence to a schedule will kill a project and cause cost over-run, so time spent at this planning stage developing accurate and realistic data will ensure a robust plan is in place. We have been through successful New Product Development (NPD) many times and can bring this knowledge and experience to benefit your project.

Once plans, budgets and requirements are set the next step has the purpose of taking several possible concepts and using a process of fact, data, research and testing to deliver a fully optimised final concept. In this stage a variety of hand simulation, mock-up, prototyping, computer simulation and early stage functional testing is used to determine the concept that best fits the project brief. This work is often split into sub systems to ensure every system is studied and the best choice is delivered. The output of the concept development and evaluation stage is a design brief that outlines the key functions and behaviours, and data proves each sub system and the entire assembly have a high confidence of meeting all targets. The process of risk mitigation is followed at this stage and backups of any high risk area can be built into the development process to ensure success. This "Functional Model" is a key milestone.

Once Functional Model development is complete the learning inputs into the design release milestone for prototype version 1. This includes all drawings, specifications, testing requirements and the validation plan. All work so far has ensured that this prototype is optimised as far as possible before large capital sums are invested in physical testing. This methodology, combined with a strong and firm master schedule and budget plan, is the most successful way of delivering a project.

The prototype stage can take anything from a few hours to several years depending on the product and life requirements. At this stage the design release and the validation plan come together with physical prototype testing. This can be in many forms such as corrosion, fatigue, endurance, cycles, performance, etc. The stage is split into iterations and stage gates as required so the deliverable is is a final design that has achieved all targets required to move into volume sourcing and production. A correctly setup and managed prototype validation stage is scheduled together with the SoP (Start of Production) so long lead tooling elements are validated first.

It is common to partner with production manufacturing companies during the prototyping phase to allow robust feedback and DFM (Design For Manufacture) input.

The end result is a fully validated production version of a product with a traceable and robust history. This allows Independent Engineer, Investor and Due Diligence specialists to support the project. This is especially critical for large scale projects that require significant investment in production tooling to achieve launch.