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Phases

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Research & discovery

An ethnographic expedition. 

We dive deep into your domain to observe the world from your point of view through a designer’s lens. We immerse ourselves in the social and cultural world of the people who will use your product.

Empathic observations uncover blind spots, pain points, and unvoiced desires — data points we use for the next phase of development. Understanding the user’s needs allows us to avoid the pitfalls that lead to product failure.

Tasks & Activities: 

  • Competitive landscape survey
  • Ethnographic research
  • Empirical data collection
  • Literature and patent review
  • Technology review
Next

Concept exploration

Creative thinking at play.

We use our understanding of your users’ needs to imagine better futures and better experiences. In this phase, the most implausible ideas can inspire the most innovative solutions.

We use sketches to problem solve. Ideas begin to take shape on paper as we play with form-factors. Free-form sketching allows us to identify challenges and iterate quickly before getting too deep into a solution. By the end of this stage, the product champion will be able to show the design to stakeholders and build excitement, momentum, and buy-in.

Tasks & Activities: 

  • Idea generation
  • Concept development
  • Refined/precise sketching
  • Thumbnail sketching
  • Detailed colour renderings
  • Marketing and branding support

Next

Cortex simulation hub

Virtual validation. 

Physics-based simulation empowers design engineers to make better decisions — a key way that we boost our clients’ ability to meet cost targets, stay on budget, and beat their deadlines. With our simulation services, you no longer have to guess at how your design will perform under real-world conditions (Mechanical, Thermal, Electromagnetics, Optics and Fluid Dynamics). It allows you to iterate fast, incorporating as many design changes as you want, confident that you’ve made the best-informed decisions possible.

Immediate impacts:

  • Understanding trade-offs without waiting for prototypes
  • Optimization of components and products based on advanced knowledge
  • Identification of problems early during the development process
  • Enablement of innovative ideas
  • Increase in lifespan and reliability of your products
Next

Prototype design

Learning through building. 

Concept exploration gives you a sense of a product’s look and feel, but nothing is more impactful than a physical prototype you can hold in your hand.

Additive prototyping using in-house 3D printing allows us to quickly test forms and ideas. Subtractive (CNC) prototyping using production-grade components brings material, texture and colour together for the first time. Our electronics and firmware engineers animate the prototypes. You now have a form factor and workable design to bring to stakeholders and potential customers. 

Hey. Now it’s real.

Tasks & Activities:

  • Mechanical verification
  • Rapid prototyping
  • Schematic and PCB design
  • Firmware and software authoring
  • Field testing

Next

Production design

Art meets engineering.

We determine how to produce your groundbreaking product at scale. Design for manufacturing (DFM) principles guide our analysis of each part for material selection, manufacturing technique, and finish.

Design for assembly (DFA) principles guide our detailing of sub-assemblies. Our engineers break an assembly down into its component parts to produce a CAD database and bill of materials ready for production. We perform regulatory checks with nationally recognized testing labs (NRTLs), as well as manufacturing validation with our supply chain, to arrive at a production-ready design that meets cost and quality constraints.

Tasks & Activities: 

  • Recommended manufacturing tools and processes
  • Materials and colour selection
  • Production-ready 3D data 2D drawing package
  • Supply chain validation
Next

Production Liaison

Boots on the ground.  

We work on location with our injection molding, die casting, metal stamping and forming, PCB and PCBA partners to ensure production vision and quality are maintained. Quality audits and close communication help ensure our partners meet the Product Requirements Document (PRD) specifications.

We oversee production on your behalf to ensure all specifications and procedures are met and followed.

Tasks & Activities: 

  • Vendor assessment and qualification
  • Internal and external quality audits
  • Production quoting
  • ISO compliant CAPA and RMA documentation handling
  • Onshore and offshore manufacturing support
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Contact

Design without production is meaningless.

Production without design is fatal.

Get in touch to learn how we've integrated these processes for our clients.
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