Phase 2: Proof of Concept

Technical questions

Once the prefered concept(s) are chosen, in most cases there will still be questions that need to be answered before detailed design can begin - questions that can only be answered by actually building and testing a physical model or breadboard.

Our in-house workshop - with amongst other tools a milling machine and lathe - allows us to quickly create functional models to proof our product concepts can be made to work. In this phase electronics tend to be based on evaluation boards, plug-boarded or hand-wired on veroboard. For optical systems we tend to use Micro/Nano bench - modified where applicable.

Most proof-of-concept models focus on one or two critical aspects of the design - they tend to be far from integrated prototypes that would not be cost-effective to build at this stage.

Styling concepts and usability

Apart from a technical proof of concept, we also want to start with the industrial design. We'll make mood boards, design sketches, renderings and non-functional handling models that can be used to obtain user input - most valuable before the actual detail design starts as we still have a large degree of freedom. Card, foam or clay models will be made in-house, supplemented by rapid prototypes where required.

Phase 3: Detailed design & engineering

Detailed design & engineering can only start once the product is well-specified and the remaining technical risks are acceptably low.

We use a 3D-CAD system for mechanical design, and an electronic design package for schematic capture and PCB layout. For on-going communication with the client team we use a OneHub secure online collaboration forum.

Each project will have its own priorities and challenges, and we will try to use the most appropriate design and engineering tools for the situation. These include Risk Analysis through FMEA and FTA; mathematical modelling using FEA or MathCad; DFA, DFM and other "design-for" flavours; Value Engineering, and the use of mass-produced parts for low-volume products.

Depending on the product, phase 3 will see the progression from distributed lab models (e.g. a processor board to enable embedded software development) to fully functional integrated prototypes, ultimately made according to production intent. These will be partially made in-house, but later prototypes are typically assembled from parts either made according to our drawings or procured from suppliers.

The deliverables of phase 3 are a Reference Prototype with a full Engineering Documentation Pack, followed by a comprehensive design review. It has to be said though that the distinction between phases 3 and 4 is typically fuzzy, as insisting on an absolute design freeze before any production commitments are made can delay market introduction - the risk of changes needs to be weighed against cost of going ahead.

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