I recently caught up with our customer Canard Design and came across this brilliant article on their blog about the 5 stages of the development process. Written by Canard MD Simon Hobbs it demonstrates how to take your idea from design to manufacture in 5 stages and is highly relevant reading to all those in the design industry or anyone looking to design products in the future this article is the blueprint and deserves to be shared...
"No matter how innovative or exciting an idea, getting it from design to manufacture and onto the shelves is a complex process with potential pitfalls along the way. This is why many organisations and individuals choose to use a product design consultancy to help make their ideas a reality.
When you bring your idea or product proposal to a design consultancy, ideally you will have an existing route to market, a potential customer base and a budget within which to work. You may also have in-house skills which will enable you to advise and work with the designers – although this isn’t essential to the five stages of development that we recommend.
The 5 Stages of the development Process
Before embarking on the process, the first step is the exchange of a non-disclosure agreement. In most cases, the design development process breaks down into five principal phases with a clear aim at the end of each stage so both parties can decide how to proceed. Sometimes the initial phases of the development process have already been carried out so only prototyping services, CAD data or technical drawings are required. However, this isn’t always as clear cut as it might seem. Turning a 3D model into a product that is ready for large-scale manufacturing takes time and a good understanding of the production processes. This is one of the main reasons why design companies are commissioned to undertake the work. A design consultancy should also be able to optimise the cost of production tools and parts – without compromising form or function.
Stage 1 – The project brief.
Although the shortest phase of the design process, this sets the tone for the rest of the project. Clear instructions as to the purpose of the idea, parts that should be included in assembly and any particular aims are all useful for the designer. This feedback often comes from end users who may have a wide range of valid opinions that need to be considered throughout the design process. The brief should also include key details which are essential to make the product work efficiently.
A good brief should outline:
• what the product will do and how
• any specific technology to be incorporated
• knowledge of any products or components with which the new product must be compatible
• any official standards with which the product must comply
• end user requirements
• the unique selling points of the product.
Stage 2- Idea generation.
Once the brief is agreed and signed off, the designers will begin to provide ideas for the product, working within the parameters and specification.
Cost is a major consideration and the manufacturing process will also influence its form. For example, injection mouldings require a draft to enable the removal of the part from the tool. Metal fabrications have limitations on folds on corners and may need to include welds whilst aluminium extrusions can have limited detail unless they are post-machined, which adds to the cost.
Our designers at Canard usually propose two or three alternative forms at the ideas generation phase. These consider all the parameters set out in the brief, but without the detail at this stage. Proposals are often modelled by using simple block models in blue Styrofoam or prints from a 3D printer. This takes initial outline data from the CAD files and lays down a binder in a thin layer of fine powder. As each layer is added, a three dimensional form is generated which is then made more durable by applying finishing materials once out of the machine. This gives a quick way of assessing the form, dimensions and general layout of the design without having to engineer parts or model them using more costly methods.
The ideas are presented as outline sketches, sketch models and 3D CAD files. Where appropriate, rigs may also be made to solve specific problems or demonstrate solutions to challenging problems. These are working models that assist in the communication and allow the designers to demonstrate how a mechanism or principle may work.
Stage 3 – Concept development.
A project often benefits from reflection time at the end of the ideas phase to decide upon the preferred option for development. The concept development stage then allows time for ideas to be consolidated into one cohesive product and to add any detail not fully considered or checked at the ideas phase. This stage may also involve a number of more detailed models which could include another 3D print or another form of rapid prototype called an SLA (from stereolithography apparatus) or SLS (selective laser sintering). There is also a process known as MLS (metal laser sintering) which produces a metal component in a similar way. All these processes can seem expensive, but enable parts such as mouldings or die-castings to be checked before investing in tooling.
CAD files such as Pro-Engineer or Solidworks are frequently updated during this phase to produce the necessary files in order to make the rapid prototypes. These files go through a series of amendments before the final versions are submitted to the relevant manufacturers for quotation. The quotations allow the designer to compile a costing spreadsheet which provides an accurate idea of final costs for assessing the selling price.
Stage 4 – Working models, block models and prototyping.
Following approval and signing off of the concept, further more detailed prototypes may be made and used for test purposes, or for market research and feedback before final tooling is produced. Depending on numbers required, this is likely to be a series of vacuum castings, a process by which a silicon tool is produced from an SLA master. The tool made is suitable for 25 to 30 mouldings depending on their complexity: more complex components are likely to wear more quickly and therefore allow fewer parts to be made. Sometimes this method is used to produce one hundred or so units, but four or five tools may be required in order to achieve this.
Testing the product is vital and it is important to use an impartial test house at the appropriate time. Canard can recommend organisations that provide this service. Packaging, instructions, servicing and CE Marking or self-certification are also important factors to consider at this stage and the prototypes can be used to gain relevant feedback.
Stage 5 – Compilation of manufacturing data.
The fifth and final design stage entails the compilation of data for the manufacture of all components, including 2D drawings, computer files, Bill of Materials, costings and any other data generated during the design development.
However, the project isn’t necessarily complete until it is launched and sold to the intended end user or customer. A design consultancy can provide valuable input at the production stage and is often called upon to check components and ensure that the product works effectively.
Whatever your product, your tenacity and collaboration with an innovative design consultancy will prove vital to overcoming any challenges you may face during the design and manufacturing process – and to achieving success."
There's plenty more interesting articles on the Canard Blog please click the following link to visit www.canard-design.co.uk/product-design/news