Product Development

Count on our proven process and expertise.

Derived from 25 years of product development experience and validated by 750 product designs, our product development process is proven to maximize efficiency, cost effectiveness, and manufacturability. What’s the key? We plan for manufacturability from the earliest design stage forward. Using in-depth and ongoing analysis, we curtail the pitfalls that often plague product development—the undetected issues that result in costly redesigns and multiple prototypes.

Experts in a wide variety of materials, manufacturing processes, and technologies—such as plastics, mechatronics, and fluidics—and adept at engineering for demanding requirements—such as ruggedness, waterproofing, and extreme thermal conditions—we're uniquely qualified to tackle even the most challenging projects.

Our team will take your product from inception through production, or we can lend our expertise at any phase of development.

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Analyze early. Analyze often.

Conceptual design

Studies show that at least 70% of a product's cost is determined during the concept development phase. Applying their extensive and diverse expertise, our senior engineers evaluate the labor and materials cost for the concepts developed.

We also analyze other key metrics such as performance and reliability projections, form factor impact, from both a qualitative and quantitative perspective. As a result, you have the information you need to evaluate each concept thoroughly, and choose the one that best meets your aesthetic, performance, and fiscal goals collectively—all before detailed design begins.

Detailed design and prototyping

Once we jointly select the concept(s) that best suit your needs, we move to the detailed design and prototyping stage. Using an array of analytical methods—including proprietary tools—we conduct in-depth engineering analysis and simulation throughout this design phase. Examples include thermal analysis, motion study analysis, and finite element analysis to identify potential stresses, deformation, fatigue, and breakage. By continually assessing the viability, costs, and performance of the design as well as consistently looking at manufacturability, we dramatically reduce the number of prototype spins required. In fact, prototyping is used to validate the ongoing analysis and simulation work—all with an eye towards production.

Development and deployment

As the design is further refined, engineering analysis/simulation continues to ensure that performance, manufacturability, and cost goals are achieved. Our extensive relationships with contract manufacturers and component suppliers worldwide enable us to integrate material and manufacturing information into the development process from product conceptualization forward. As a result, time to manufacturing and overall development costs are reduced— with fewer tooling iterations.

Manufacturing engineering

We act as your engineering support team for products in production, working with both your organization and your suppliers and manufacturers, to address issues that may arise in the manufacturing process, reducing the burden on you. From addressing yield, performance, or quality issues, to improving efficiency, we can help you manage your production process.

If you're manufacturing your product in Asia, our China-based engineering team—who is involved in your project from the beginning—makes the transition from development to manufacturing fast and seamless.

See our product design approach in action.

Optimal Assembly

Learn how assembly time and costs can be predicted earlier and more accurately by combining DFM and DFA principles with theoretical modelling.


Experience the Acorn Advantage

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