Product Design & Development

After an enquiry, an initial discussion is undertaken about the project for development or a technical issue that requires resolution. We would determine the attributes the product would need to have, including its planned service life and environmental impact. Consideration would be given to the use of recycled or bio polymers. There are no costs associated with this initial activity.

We will outline of our proposed solution and discuss any design, production and material considerations. Compliance with legislation will be considered.

Budget or actual costs for development work, production tooling (both the mould tool and any post moulding jigs or fixtures), material selection, piece part costs and any added value activities will be itemised and agreed. An agreed solution is reached with the client. There are no costs associated with this activity unless we are required to produce a conceptual design.

If the client does not have detailed CAD drawings, we will produce CAD models of individual components and any assemblies including any subcontracted components. The number of elements in any assembly is kept to a minimum, and where possible, allowances made for the product’s end of life disassembly and recycling.  This may be to meet the requirements of legislation, such as the end of life vehicle directive. Costs would be agreed upon with the client.

CAD drawings can generate a rendered image of the product. Visual analysis can then determine any issues relating to tool design, production and part manufacture. FMEA studies will help predict and rectify any problems, and tool drawings can be generated and analysed to ensure consistent part quality and repeatability. Once adjustments are made, prototype components can be produced using techniques such as 3D printing.

Finalised CAD data is used to manufacture production tooling. Tooling trials produce a small ‘sample’ of components that can be studied using metrology and reporting techniques such as CAP (Capability) Studies. If parts are out of tolerance or don’t meet other specified requirements, then tooling is modified and re-sampled. This process is repeated as necessary.

Once tooling and components are ‘signed off’, a schedule for parts manufacture is agreed.  Free issue or outsourced components required to make the product is put into stock, and necessary assembly or testing equipment procured.  Before moving to full-production levels, pre-production runs may take place.  These are sometimes required for field and laboratory testing or pre-launch marketing activities.  Production runs of 100-200 components are typical.

Production tooling will be stored and put into production as required.  Prior to this, raw materials and packaging materials are procured, and transport schedules and costs agreed.