How We Work

Initial contact to quotation. On contact, we assess whether we can supply the service you require. A non-disclosure or confidentiality agreement is signed (if appropriate) at this point as we respect and protect your intellectual property. This protects your intellectual property rights while allowing us to discuss your project in detail. A quotation is then prepared based on your detailed requirements and may involve a face-to-face meeting or communication by phone and email. A draft copy of our standard contract is made available at this point so any issues can be addressed up-front. If our quotation is accepted, we prepare a standard contract that works with the quotation.

Requirements. Once we receive your order and design begins, all specification and requirement information is gathered, reviewed and updated as development progresses. This information is used to guide the project.

Design study. Here, the requirement information gathered earlier is used to guide design concept development and evolution. The aim is to extensively explore and brainstorm ideas and concepts until the best is found for development. During this design process, many disciplines are employed from practical model making/prototyping to freehand drawing for design studies, problem solving, meetings and industrial design to complex computer software for engineering design and simulation. Suppliers are often involved at this early stage to help build involvement and tap into a flow of ideas. It also helps to avoid expensive and time consuming changes later.

3D CAD design & simulation. Design is checked for interface with the real world by simulation. We use 3D computer models to confirm form, fit, function and aesthetics or analysis of a particular function such as deflection or stress. Solidworks with Simulation is our main CAD system for design and analysis. This is central to the design process with data feeding into and out of the CAD system.

Throughout the project we can send you 3D viewing files so you can give feedback and see progress. These allow you to view and manipulate our work on a standard computer and perform measurements, rotates, pan, zoom, sections, explodes etc all in full colour 3D. All items that go to make a product are defined at this stage along with their materials and processes. Suppliers are engaged as early as possible for mutual benefit, aid understanding and to address design and manufacturing issues at a point when changes are easy and cost efficient.

Prototyping. Products we work on range from something you could hold in your hand to large structures and fabricated products measuring 10s of metres.  So the most appropriate prototyping process is used for the product in development. For a lot of small products, most of the 3D printing processes currently available are used such as SLA, SLS, DMLS, FDM, vacuum casting etc. These are complimented by CNC and manual machining or conventional model making. Sheetmetal and welded assembly prototypes are often processed with a sheetmetal or fabrication supplier, especially when large. CAD simulation is vital in developing these products as sometimes a prototype is not feasible. There needs to be enough prototyping to adequately cover and prove out development. Prototypes are sometimes required at several stages during a project. This may vary from a single part for design validation to a small batch for product testing. Prototyping cost must be established at the project start as a balance has to be struck between prototyping and the risk of addressing problems later in the project when parts may have been tooled and are in production. It is well known that the cost of correcting a problem escalates as a project evolves. After tooling, it is many times that of correction at the prototype stage which in turn is many times that of a design stage correction. Suppliers such as toolmakers are involved here as the design benefits greatly from reviewing a physical model.

Testing. There are many occasions when testing is required but it broadly falls into two areas, development and production.

Development testing. Resources need to be available to make full use of prototypes. This is a good opportunity to check the CAD system Bill Of Materials (BOM) as all components are purchased and built to it. By doing this, the product purchasing, part count and specification are checked at an early stage – valuable when there are long leadtime items to be ordered. All interfaces, form, fit and function are checked including electronics that can be in the form of Printed Circuit Board (PCB) mock-ups with dummy connectors and wires. Sometimes, further prototype cycles are required via a design change to prove out any problems found. Sub-assembly or component tests are often setup to prove a specific element. Approval testing may also be carried out at this stage via an approved test house (Notified Body) if certain standards have to be met.

Production testing. This is carried out wherever possible using early production components often mixed with prototype parts to supplement, depending on production part availability. This is used to validate design, purchasing and production. The whole product is finally checked and tested with all production parts for form, fit, function and conformity to required standards.

Detail design. CAD is central to this stage and SolidWorks (our main CAD system) is used extensively. Here, all the preceding work and knowledge is amassed to develop the design to a production standard. Output is a mixture of 3D model data, documents and drawings that are either fully detailed or a reference drawing accompanying a 3D model. Reference drawings convey only data that cannot be defined or easily visible in a 3D model. This greatly simplifies the design documentation and reduces leadtime. During development, the detail design is kept flexible under a prototype revision system. Once the design goes to production, the revision system changes and is under formal engineering change control.

Manufacture. Early supplier liaison comes together at this point. Any queries are dealt with swiftly as the communication paths are established. CAD data is vital and a central reference at this stage as it is used directly for manufacture. We work closely with suppliers to ensure all components and assemblies are tested and inspected for conformity. During early or prototype production, any problems or improvements are carefully considered and worked into production changes if necessary.