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New Product Design for Manufacturing

Design a new product to propel the business forward using design for manufacturing.

Start with an idea or a challenge and get an end-solution tailored to your target market. Design with a lean approach that fits your budget, optimised for your business goals and target users.
Click now to book two hour planning session for €199. Full refund anytime before session.
MARND disinfectant compact pump in a transparent shell, showcasing its internal components and PCB.
A woman hand pointing to a chart on a stack of papers on the table during a meeting.

Project Planning

New development project planning

Get advice on your specific idea or challenge. We listen to your challenge and recommend suitable solutions.

Planning a new product development takes into account specifics that vary from one challenge to another. Fruitful projects start with a development plan. Degree Sign planning helps you cover all initial blind spots, saving you time and money.
Click now to book two hour planning session for €199. Full refund anytime before session.

Project Planning Call

Identify project objectives, expectations, and root-causes of various challenges. Assess the technical feasibility of the project and requirements for next steps.

The project planning call also identifies additional aspects such as:
✔ Design direction, e.g. plastic vs metal
✔ Technology direction, e.g. old vs new
✔ Fabrication direction, e.g. forming vs machining
✔ First iteration/patch cost estimations
A woman taking notes during a zoom meeting.

Development Plan

Get a written plan tailored to your project. It starts with a concluded brief, and goes through the execution methodology and recommended production options.

The development plan includes a breakdown of the product development stages with their estimated cost along an expected timeline. The development plan could also be visualised as a mind map diagram.
A mind-map of a MARND product, showcasing the simplified complexity of MARND development planning process.

Research and Concept

Design research & concept

Project research allows you to find out if your challenge is practically solvable. Degree Sign research process is very comprehensive.

Start with one idea or more and get a detailed report in the form of a booklet that covers everything from challenge analysis to final recommended solutions with conceptual designs included.

Feasibility Study & Design Research

Conduct market and technology research to assess your new product idea against readily available ideas and products on the market.

The research investigates active competition and ideas that could develop into competing products in the not-distant future.
The feasibility study delivers an understanding of the industry landscape. It is also assisted by a preliminary review of past and current valid intellectual property (IP) to gauge the feasibility of designing proposed solutions.

Projects can include travel and on-site visits to evaluate challenges, where communication with end-users and stakeholders can help set and evaluate design goals. A survey of prices offered for competitor products can also be done to estimate possible savings an innovation could bring.
A line chart representing how market trends for a given consumer product can be measured.

Concept Design

Feasible ideas are shaped to achieve set goals with features selected to enhance the efficiency and manufacturability of the product.

Concepts are hand-sketched to produce helpful visual representations of those winning ideas and features.

The conceptual design is done in cycles, until a healthy number of iterations is generated, where concepts define the overall look and feel of the product.
A group of sketches for handles portion of a consumer mobility product.

Validation Landing Page

A landing page (one-page website) for the upcoming product idea using concept renders to validate market interest and gauge traction. This step ensures that the project is worth the funds allocated for it.

If no funds are available for the project the website can kick start funding efforts from individual angel investors, industry veterans, or as a place to collect emails for a crowdfunding campaign offering pre-sales of product ex. on Kickstarter.com
M2 module product landing page design
Technical design inside CAD software. Dimension of parts are represented around the drawing in white on a blue background.

Design Development

Product design development

Product design for manufacturing turns initial concepts into practical designs, using a staged design process. The process develops concepts into detailed designs accounting for all functionalities.

The design can be a single part solution or include hundreds of parts, based on its complexity. It is validated using various prototypes and tests.

Preliminary & Detailed Design

The preliminary design process bridges the gap between conceptual and detailed design. It is the initial design based on the finalised concept where all features are frozen.

The process takes place in a native 3D environment to create all supporting features. It then reviewed through mockups and draft renders to be approved for detailed design.

The detailed product design defines all intricate details, e.g. sub-components, dimensions, and tolerances. It facilitates more accurate estimations of product specifications and cost, and more importantly, allows for successive prototyping and test.

Technology Integration

Technological elements, such as electronic components, are designed and integrated into the system of the new product.

The integration process allows the development of production-ready prototypes at an early stage of the design process.

An example is printed circuit boards (PCBs) designed directly using final surface-mounted components (SMD), instead of going through breadboard iterations using larger components.

Design Prototyping & Test

Tests are initially carried out by simulating real-world scenarios digitally. These identify how parts of the new product could change or break under expected loads. They estimate design limitations and help identify possible improvements.

Under-stressed areas identified during tests are a good example. Those areas often signal excess material that could be removed without impacting functionality, thus saving weight and cost.

Physical prototyping follows, using 3D printing to create functional models to test mechanical parts. Each printing process is followed by tests to gauge parts characteristics, such as relative size, functionality and strength.

Prototype parts are initially produced on filament-based 3D printers (FDM), while smaller and more accurate parts are produced using powder-based SLS printers (selective laser sintering) or CNC machines (computer numerical control) to achieve lower tolerances (better accuracy).
Complex machine that used to mass produce parts utilising metal wires.

Manufacturing Setup

Product manufacturing setup

Final design optimisation of the new product for manufacturing. Industry-level technical drawings and files, ready to share with global manufacturers.

Produce pre-production samples and conduct deployment tests. Setup a global efficient supply chain. Manage mass production with ease up to quality control and products dispatch.

Design Review & Optimisation

Throughout the prototyping cycle, test results are reviewed to highlight challenges and areas for improvement within the new product.

The design of the new product is then improved by correcting any deficiencies and optimising parts and assemblies performance to provide maximum efficiency.

This process is cyclic and usually require repetition of prototyping and test cycle, as well. The process can theoretically be done for an infinite number of times as improvement is always the outcome. However, practical projects require the design to be frozen once the improvement between cycles goes below a relatively low percentage.
An animation of a sample electronic consumer product optimisation, showcasing the optimisation of the plastic shell along the internal electronic PCB.

Technical Documentation

Technical drawings and files communicate important "controlled" features using a universally understood format, e.g. specifications, dimensions, and tolerances.

They help suppliers understand product requirements and facilitate communicate regardless of experience level, country or even language.

These documents are usually produced in PDF format, easily printable by any suppliers and do not require any specific technical program to review. They are a crucial element in the production process. In some cases, these documents could be also be used in a legal capacity, as they can verify production quality limits.
A sample 2D line technical drawing with dimensions, all in black lines.

Pre-production Samples

Pre-production samples of the new product are made to verify the actual functionality, specifications, and product aesthetics.

Required improvements can be fed back into a design review and optimisation loop for additional samples, before investing in mass production moulds and jigs.
A photo of 3D printed SLS rectangular-shaped part that is completely transparent.

Supply Chain Setup

Product parts BOM (bill of materials) is divided according to shared manufacturing processes into several sets.

Potential manufacturers of each set are sent RFQs (request for quotation) for order placement. On-site visits are conducted to evaluate relevant preparations.
A photo of consumer product mass production line, showcasing many workers each working on a large machine.

Production Management

The supply chain is continuously monitored against a set of milestones and deadlines to resolve challenges that may arise.

Sub-processes are reviewed for quality assurance to avoid challenges in later production stages, e.g. on the assembly line.

The assembly process is reviewed for setup improvements and quality maintenance, while on-site checks ensure the production progresses according to requirements.
A plastic colour sample that was produced using injection moulding.

Quality Control

Final parts and assemblies are reviewed to verify dimensional conformity, performance, and other specifications.

For the initial production patch, non-confirming units can be a significant percentage. However, those can be replaced by a supplementary production output to achieve the required order size. Product patches that pass quality control are packaged and shipped according to requirements.
Microscopic photo of a metal part, showcasing a tiny accurate circle and a very fine edge. The part is shiny so a fraction of human fingerprint can be seen in the image.

Product Marketing

Product Packaging & Marketing

Represent new products in the best light using digital marketing material made for the web, in addition to physical materials ex. product packaging and brochures.

Sell online to reach a wider audience, control the messaging surrounding the new product and reach consumers overseas.

Packaging & Marketing Materials

Packaging represents the first user experience with the product and favouring the shipping durability over the packaging promotional appearance can make sense for some packages.

Including marketing materials, manuals and other items are equally important to be accurate and pleasant to see, if not read. Gimmicky features such as magnets in off-shelf ready-made packaging reflect poorly on the product perceived quality.

Digital marketing materials are also crucial for selling online, as eCommerce continues to grow its share from conventional retail businesses. These digital photorealistic renders are more versatile and appealing the photos, especially to highlight small features of products that might otherwise show dust in photos.

E-Commerce Website

E-Commerce is becoming a crucial part of any business, especially when targeting the mass market. Product direct selling is not just extra profitable, but also scalable. It skips the negotiation phase with bigger retailers and allows the product owner to reach consumers directly.

The eCommerce website also allows direct advertisement, reaching consumers overseas all around the globe, instead of being geographically limited. It is particularly crucial for niche products that would otherwise be limited by the local small number of potential customers.

Marketing online also allows control over product exposure. It relatively shields the product from copycat competition looking for products to copy on popular eCommerce platforms such as Amazon. New technology facilitates building automated electronic systems that handle customer journey from their order until shipping label printing.