Hardware product development

From concept to
manufacturable
hardware

Whether you have a napkin sketch or a near-finished design — we can help develop it, validate it, or get it across the line for manufacture.

From first idea to production — or anywhere in between.

Start a conversation
Enter at any stage

From a napkin sketch to a near-finished design ready for production — the six-stage process below applies wherever you start. Nothing is wasted; we pick up from where you are.

6 stages
1 · Requirements & Concept› 2 · Design & Validation› 3 · Prototype & Test› 4 · Production Readiness› 5 · Manufacturing Support› 6 · Launch & Improvement

The process

Six stages from concept to launch

Iterative and Nothing committed before it's validated. Enter at any stage.

1
Stage 1
Requirements & Concept
Requirements, feasibility, and preferred concept — with manufacture in mind from day one.
Requirements specFeasibilityConcept design
2
Stage 2
Design & Validation
Detailed CAD and engineering analysis. Tolerances, geometry, and materials decided with production in mind throughout.
3D CADStructural analysisDrawingsBOM
3
Stage 3
Prototype & Test
Prototype builds to validate performance. Results feed directly back into design — stages 2 and 3 often iterate.
Prototype buildTest planTest resultsRevisions
4
Stage 4
Production Readiness
DFM review, tolerance optimisation, and supplier alignment before tooling is committed.
DFM reviewUpdated CADProduction specCost review
5
Stage 5
Manufacturing Support
Supplier coordination, first article inspection, and sign-off before volume commitment.
Supplier coordinationFirst articleSign-off
6
Stage 6
Launch & Improvement
Engineering handover, documentation, and ongoing support for future iterations.
Engineering handoverDocumentationOngoing support
This is an iterative process, not a linear one
Each stage informs the others — concept feeds manufacture thinking, prototype results revise the CAD. Nothing is siloed. Enter at any stage.

Capabilities

What we bring

Structurally sound, manufacturable at cost, and usable in practice — DFM and unit economics considered from concept, not bolted on before tooling.

01
Concept design & CAD
From brief or sketch to detailed 3D CAD — SolidWorks, Fusion 360 — with toleranced 2D manufacture drawings.
02
Structural analysis (FEA)
Load case development, FEA, safety factor assessment, and failure mode identification.
03
Weight & topology optimisation
Topology studies to reduce mass without compromising structural performance — high value for EV and performance hardware.
04
Reverse engineering
CAD from physical hardware where no digital files exist — legacy parts, OEM components, supplier samples.
05
Prototyping & manufacture sourcing
3D printing, CNC, and fabrication coordination. Supplier sourcing for low-volume and production.
06
DFM & production readiness
DFM review against real supplier constraints — tolerances, processes, cost, and assembly.
07
Regulatory & standards support
AS/NZS, CE, ADR, and ISO standards navigation. Load case development and testing lab coordination.
08
Failure analysis
Root cause analysis for in-field or in-production failures — structural, weld defect, and wear-based.
09
Technical documentation
Assembly instructions, service manuals, parts catalogues, and calculation reports for production and compliance.

Example projects

Hardware delivered

All projects →
Zoomo One delivery vehicle
Zoomo One front angle
Frame FEA stress analysis
Suspension kinematics
Assembly drawing
Light EV · Full development
Good Design Award
Zoomo One Electric Delivery Vehicle
Award-winning B2B electric delivery vehicle — concept through production.
Full vehicle designStructural analysisSuspensionManufacture
Bike holder installed on caravan
CAD concept design
Detailed design
Wheel cradle detail
Consumer hardware · Concept to prototype
Drawbar Bicycle Rack
Adjustable caravan drawbar bicycle rack — concept to manufacture pack and prototype.
Concept designCADManufacture packPrototype

Have hardware
to develop?

Step in at any stage. Contact us to discuss your project.

Contact us Need a design review only?