Design & Development

Design and development

Our product design and development team seamlessly blend the creativity of our concepts with solid engineering. They are professional, very easy to work with and are committed to help our clients to:

  • Improve quality and reduce returns through robustly designed products that are easy to assemble and cost effective to manufacture
  • Utilise true ‘Design for Manufacture’ by simplifying tooling and production set up costs to reduce the investment being made
  • Lower on-going manufacturing costs by reducing components part count and materials
  • Ensure prompt delivery of the project by working to a structured process for maximum design efficiency and conformance to regulatory standards
  • Utilise best-practice design management to leverage the efforts of all involved, ensuring your project is delivered on time and to develop your projects as cost effectively as possible

Design development phase 1: design for prototype

The design for phase 1 of a product is likely to be novel and innovative so will need prototyping to establish proof of concept whereas a specialist project will not have the luxury of a prototype stage.

Phase 1 may require more than one iteration of prototypes as testing and usability studies can show unexpected results. Sometimes the prototype may fail testing yet still afford enough learning to move to the optimisation stage. The prototype may also be more successful than expected so allowing material or features to be removed, things often evolve and change as part of this phase of the development process.

Design development phase 1: output

Generation of a 3D design and CAD models sufficient to allow prototypes to be manufactured efficiently. The 3D models will be tailored to suit the materials and manufacturing techniques most closely mimicking those used for the final product. However will often not fully consider all tooling and production requirements which will be undertaken in phase 2.

Design development phase 2: design for volume manufacture

After the prototypes are built and tested we learn from the assembly process to obtain data from which we can optimise the design. The optimisation process may purely be to adapt the prototype CAD models to a simple volume manufacturing technique or to make slight dimensional changes. This is often quick and simple to do. However it is also common for 3D CAD models to be regenerated from scratch to match different material, tooling and production requirements. High volume products generally need very robust design practices and testing to ensure regulatory and quality requirements are met. This is likely to require further FEA work to check strength or fatigue. Tolerance analysis to ensure features and products will perform properly across the tolerance band which chosen manufacturers can achieve. Assembly Analysis may also be required too, this will establish how components can be assembled efficiently. Haughton Design has the knowledge, experience and accreditations to ensure these processes are done correctly for our clients.

Design development phase 2: output

Refined 3D design and CAD models with necessary assembly fits and features for volume manufacturing techniques. The CAD models should have features fully designed and engineered to allow products to be easily assembled and finished ready for Testing and then Industrialisation of the product.