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Roadmapping the Product Development Journey A Step-By-Step Guide for Bringing Product Ideas to Life
Roadmapping the Product Development Journey
A Step-By-Step Guide for
Bringing Product Ideas to Life
Introduction
Milestone One: Research the Idea Search the Web Search for Patents Gauge the Market Timing
Milestone Two: Research the Cost Design Engineering Prototypes and Samples Materials Processing Costs Testing and Certification Shipping Packaging
Milestone Three: Prototyping Prototyping Phase One Design Files Prototyping Phase Two
Milestone Four: Sourcing a Supplier Look for a Specialist What About Communication? Ask About Minimum Order Restrictions Material Verification Research Pricing
Milestone Five: Production Design for Manufacturing (DFM) Tooling Tool Sampling Finishing Inspection and Testing
Journey’s End
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Star Rapid has worked with with thousands of clients over the years, helping them transform their designs into finished products for applications in the fields of aerospace, automotive, industrial, medical, consumer products and more. However, we’ve found that even companies experienced in product development can face unnecessary and avoidable roadblocks because they didn’t have a proper guide to help them anticipate, and plan for, the demands of advanced manufacturing.
That’s why our team of professionals created this white paper, to make the product development journey easier and more rewarding. Regardless of your industry, we know you will find that laying out all the procedures in a clear and logical way will help you to stay focused on your development goals and achieve the results you want quickly and efficiently.
3Milestone 1
Research the Idea
Milestone 2
Research the Cost
Milestone 4
Sourcing a Supplier
Milestone 3
Prototyping
Milestone 5
Production
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Introduction
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Search the WebFortunately there are many resources to draw upon to assist in this research. Check out the internet, of course, and use multiple search engines and browsers. Different search engines will prioritize different keywords and phrases, thereby producing different search results. Focus your search criteria with advanced queries to refine search parameters.
It is also possible to hire the services of outside vendors such as LexisNexis to search electronic databases in greater detail. Eventually this will lead you to the next step: has the product idea already been patented?
Search for PatentsIf you are reasonably confident that this product idea is unique, then the next step is to do a patent search. This will cost some money, but is absolutely necessary for protecting yourself or your firm against the potential legal liability of violating someone else’s patent or copyright. It also provides you with the legal basis for protecting your own idea against infringement.
Milestone One: Research the Idea
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Developing a product from scratch is a major investment. If you’re bringing a new product idea to market, at this first milestone we encourage you to spend some time to research how viable the idea really is. For products that aren’t intended for the retail market, it’s still wise to perform due diligence to ensure that your solution doesn’t already exist in a similar form.
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Remember, an idea may have been patented even if a commercial product was never generated from that patent. Do your homework now for peace of mind later.
Gauge the MarketIf you’ve developed a commercial product before, you may have discovered that even some great ideas don’t necessarily become big sellers. Why is that? Because product inventors have a vested personal interest in believing that their idea will be a huge hit, and may often pursue this idea even in the absence of a compelling market rationale.
If the product concept is a novel one, we recommend a conservative approach when calculating potential sales and hence the amount of initial investment that is warranted in its development. This same general advice also applies to industrial components, which may not answer to the same market forces but will nevertheless require the same commitment of resources.
We have found that it’s easy to get caught up in minutia when it comes to product development, focusing only on short-term issues rather than the full product lifestyle. At the start of a project, a wide view is the best way to anticipate, and avoid, pitfalls.
TimingDo you have a deadline for the development of this product? Only you know what the intended market is, and whether there is a limited window of opportunity to get the product out there. Your forecast on time-to-market must be carefully considered, since it will greatly affect many other aspects of the project.
There are many ways that a manufacturing supplier can help you to get parts faster, if that is your priority. But to do so may require compromises in other areas. For example, some materials are easier and faster to process but are less durable. Or, a manufacturer can make a fast turnaround order in limited quantities but you might pay a premium for that service. Again, you need to be clear about your development priorities and then create a realistic schedule and budget around them.
In general it’s a good idea to budget more time than you think you will need. Patience is key since there may be unexpected delays along the way.
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Milestone Two: Research The Cost
Design EngineeringYour manufacturing partner will rely on your 2D and 3D drawings to create your parts. These drawings need to be watertight, and contain all the data necessary for production. Any data that is incomplete, inaccurate or unclear will potentially become a delay or a product defect later in the journey.
If you have in-house CAD design engineers, that’s one expense you can avoid. (And maybe you are that person!) If you don’t have access to this expertise, then by all means budget for it.
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The second step in the research phase involves doing some cost calculations. Determining cost is a complex process and, by its nature, will be an approximation at this early stage. As with timing, it’s wise to err on the side of caution and budget for more money than you think you might need.
Unless you’re a product development veteran, our advice is to keep your goals modest in the beginning. The main reason is that you will want to limit the number of variables in order to control cost and quality. In addition, if there are many processing steps that might mean using multiple suppliers. This too can increase your costs and make the management of your project more challenging.
Our second tip is that you take your time to go over every variable in as much detail as possible. This is good advice for your first product development journey or your one-hundredth. Effort and care at this stage will save a great deal of time, trouble and money in the future.
Here are the major cost drivers to consider.
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Snuff Box Prototype Made Using CNC and Injection Molding
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Prototypes and SamplesA prototype can be as simple or as complex as you need it to be. Some are made just to get a good look at an idea cosmetically, while others are needed for testing functionality and performance. For completely new product ideas, prototypes typically start off rather basic and then gradually progress in complexity and cost as they evolve to more closely resemble a finished production part.
Fully-functional prototypes can in some cases be more expensive and time-consuming to manufacture than their mass-production counterparts, since they don’t benefit from economies of scale and may require more intensive hand-work.
Some products won’t require prototyping per se, but multiple samples will still be needed for measuring and testing against the original design.
MaterialsIt is important to clearly specify your choice of materials at the outset of a project, and whenever possible to avoid changes of material halfway through the development process.
Why is that? Because different materials may require much different methods of processing, which in turn can create a cascade effect involving tooling costs, engineering and design considerations, minimum order quantities and many other factors
Also, if possible, avoid combining too many different material types together in one assembly unless you have a lot of experience in development. Not only does this add to material and production costs, but
it can also create unanticipated difficulties with material incompatibility. For example, materials expand and contract at different rates as temperatures change. This can potentially make it hard to control dimensions when different types of material are being manufactured with separate processes and then later combined into one assembly.
More information about how to choose the right material for your project can be found here and here.
Also, be wary of falling into the trap of saving a few pennies by choosing a less expensive alternative over a superior grade of material. It is better at this time to focus on material performance rather than material cost. Later, should your product become successful, there will be other opportunities to economize over larger production runs.
Processing CostsAgain, keep it simple but aim for high quality, not low cost. If you have engineering or production experience, you may already know what it takes to get a part made.Saving money with cheaper labor rates may compromise the integrity of your parts and should be avoided.
Testing and CertificationDepending on where and how the part is used, different types of products may need to conform to different legal and statutory certification schemes. Know what they are in advance and set resources aside for the necessary application procedures and testing fees.
ShippingIf the supplier is just across town, shipping
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costs will likely be reasonable and there won’t be import duties to worry about. But if they are located on the other side of the world, you must account for shipping costs and for the corresponding delay between production and receipt of goods. This cost is amortized over the number of parts that can be fit into a standard shipping container for sea freight.
Air shipments are based on weight and can be prohibitively expensive, so this option should only be used when parts are urgently needed. Therefore, avoid urgencies by planning your production needs well in advance.
PackagingEven if a product is not for retail sale, it still needs a box, carton or wrapper of some sort. Of course, if the product will go on a retail shelf, the packaging can become increasingly complex and colorful, and therefore more expensive. Buried within each of the above categories will be hidden costs that are variable and unpredictable. We advocate a conservative approach because it is better to be pleasantly surprised than disappointed. We have also found in our experience that careful planning and accounting in the beginning is a great way to ensure the most economical results in the end.
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Smart Lock Prototype Made with Pressure Die Casting
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Prototyping Phase OneEven some of the world’s most advanced industrial design studios make liberal use of simple paper and clay mock-ups to dial in just the right look and feel that can be hard to model on a computer screen.
Also, be prepared to make many design iterations as an idea evolves. It’s not uncommon to make dozens or more at this stage, and all of them serve a valuable purpose in perfecting a concept before committing to production.
Design FilesOnce you arrive at a prototype design that you like, the next step is to prepare your design files. These should include both 2D and 3D drawings. 2D drawings should contain all relevant dimensions of all features, tolerances, surface finishes, color, etc. It is best to be as specific as you can. For example, specify a radius of .5 instead of saying “rounded corner”. Don’t say “smooth” but give an exact Ra value or surface finish number from SPI.
This section applies to product developers who are designing a new product or product concept from scratch and for whom prototyping is an essential part of the journey. In may not apply to all, but there is valuable information here that can offer insights about design thinking and strategy.
Milestone Three: Prototyping
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Enclosure Made with Polyurethane Vacuum Casting
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Generic language or assumptions on your design drawings will later require exact clarification with your manufacturing partner, so this is a good way to save time and prevent later costly misunderstandings.
3D CAD models also need to be watertight. This means that all lines, planes and features must be connected with no gaps. Drawings that are not watertight cause delays and potential errors.
Finally, note that it’s counterproductive to specify too many critical dimensions for any given part feature or plane view. Critical dimensions in multiple areas tend to “fight” one another and can only be achieved under very controlled conditions at exponentially higher cost, which is not justified in the vast majority of commercial products.
More information about preparing your design files can be found here.
Prototyping Phase TwoDepending on part complexity and the kind of testing you require, consider making a 3D printed prototype. Plastic printers using FDM or SLA technology can produce reasonably accurate physical models quickly and inexpensively. Such printers are becoming quite common, and if you don’t have one at your own facility there is a good chance that a service bureau is nearby.
In most cases, it doesn’t make financial sense to outsource 3D plastic printing of prototypes to overseas suppliers. Factoring in shipping costs would make this option more expensive, and should only be done if the supplier will then use that part as a master pattern for a
subsequent casting process. Another advantage to 3D printing is that it’s also amenable to making quick design alterations without incurring the expense of fixed tooling. More information about the benefits of 3D printing for prototyping can be found in our blog, here.
If you need a prototype for more robust engineering or functional testing, consider CNC machining. Such a part can be fully functional and made of virtually any material. Look for machine shops or prototyping specialists who are happy to make one-offs if you don’t have in-house machining services.
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Robotic Exoskeleton Designed by IHMC and Using CNC Machining
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Milestone Four: Sourcing a Supplier
It’s time to find a manufacturing supplier who can turn your design into a truly finished part ready for mass production. But how can you be sure that you are working with the right one? We put together some key points to help you narrow down your search.
Look for a SpecialistYou will want to work with a supplier that specializes in new product introduction. They are likely to have a suite of services optimized to support small volumes of highly custom parts requiring many finishing options. They are also accustomed to working closely with developers and resolving design and/or production issues as they come up. Beware of anyone offering a “take it or leave it” quotation without support services.
What About Communication?When it’s time for production, one of the most important considerations is being able to explain what you are trying to do, and work with someone who “gets it”.
This is especially critical if you are considering a supplier who is far away. You will need to talk clearly with someone who understands your concerns, anticipates your needs and is able to respond quickly and to the point. This will help enormously to relieve anxiety if you are not physically present to see your parts being made.
It is also a great advantage if your supplier has a local sales representative to be a liaison between yourself and the production facility and is always available to address any of your concerns.
Ask About Minimum Order Restrictions Many manufacturers will require minimum order values or quantities. This is because larger facilities have operations that are optimized for mass production of large volumes, and therefore their minimum order values may be correspondingly high.
Make sure you target suppliers who do not have minimum order restrictions, or at least ensure that you know about them in advance. This can also apply to raw materials. Stockists of raw materials may not release small quantities but only sell by the ton, for example. This in turn will influence how many parts you will be obliged to commit to in your first order
Material VerificationMaterial verification means that your chosen supplier is able to offer you comprehensive evidence that all the raw materials they use have been inspected and verified using the right equipment and techniques. This is especially important if you need a specific grade of material to conform to engineering standards or to pass safety certifications. If they can’t or won’t provide documented verification data, we advise looking elsewhere.
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Research PricingDo your homework. Look for manufacturers with a track record in new product introduction and prototyping. See if they have a gallery of their work online, with case studies, technical white papers or other useful information that not only shows their services in detail but also demonstrates their ability to work with various industries.
It’s a good idea to send out requests for quotation to as many companies as you can. Be sure to provide as much detail about your project as possible. The more detailed you are, the more accurate the quotation will be. If your potential supplier asks you for more information or points out discrepancies, this is probably a good sign. It shows they are careful and paying attention. Also, the more pricing information you have helps to establish a median figure you can use as a basis for further comparison.
Beware of prices that are too low. This suggests that someone is cutting corners somewhere, and could spell disaster. Again, invest in getting a quality product, not in looking for the lowest price.
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Milestone Five: Production
Once you find a supplier you trust and a quotation you can accept, it’s time to go into production. Regardless of what process you use to make your parts, it’s first necessary for your supplier to review your design drawings carefully to ensure manufacturability.
Design for Manufacturing (DFM)What do we mean by “manufacturability”? The processes and materials that are suitable for mass production may not be the same ones used to make a prototype. Mass production places a premium on repeatability, using common tools and equipment to provide consistent results over larger volumes with minimal expense. This means that your design must be optimized to suit.
The DFM review is a great way to refine your design, while also offering valuable insight into the professionalism of your supplier and their attention to your needs. During the DFM review, your supplier will identify areas in your digital drawings that may need to be modified to improve manufacturability.
For more information about design for manufacturing, consult our white paper.
ToolingSome products require an investment in hard tooling, either aluminum or steel for plastic injection molding or steel for pressure die casting. To learn more about choosing the right tool metal for plastic injection molding, see our blog here.
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Enclosures for a Drone-Mounted Agricultural Sensor
errors or delays.
Inspection and TestingReliable suppliers will apply best practices so the quality of your parts are monitored and ensured at every step. Only after passing through each of these steps does a product come to final inspection, where you should be issued a comprehensive report verifying the exact dimensions, tolerances and surface finish of the parts you ordered.
Depending on the application of your product, there may be other rounds of testing necessary, such as engineering, performance and durability tests. Once you have production parts in hand, you will also need to submit them to the relevant authorities for safety certification, where applicable.
Tool SamplingOnce a tool is completed, your manufacturing partner will use it to make initial or T1 samples.
These first pieces are used by the supplier to set up the many parameters on the machine that affect part quality: pressure, temperature, cycle time, etc. Once they dial in the process, they will carefully measure the parts and send you the results for your approval.
It’s not uncommon to discover small modifications to the tool that need to be made after the T1 samples. These can include altering the location of ejector pin marks, increasing draft angles, moving parting lines and a host of others that aren’t always obvious during the design phase.
Normally, new product development requires a few rounds of testing and tool modification to achieve repeatable results that meet your satisfaction. That’s why we recommend using good design practices from the beginning, while working with a supplier that you can communicate effectively with.
FinishingYou may require additional work like painting, anodizing, drilling and tapping holes, plating, polishing, etc. Suppliers that specialize in prototyping and new product introduction typically have all of these services under one roof so they can offer you a comprehensive one-stop solution.
This is preferable to using multiple sub-contractors. Dealing with many suppliers at the same time makes the product development process much more complicated while increasing the potential for
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Laser Scanner Being Used for Precise Measurements
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One journey has come to an end, but a new and exciting one is just beginning – bringing your product to market and reaping the rewards of all your hard work.
We hope this guide has been helpful to you in planning your product development strategy. We love to collaborate with world-class engineers and designers who are making the next generation of innovative solutions for a wide variety of industries. And as we continue to learn from these collaborations we will continue to share this information with our partners to support them at every stage.
Journey’s End
