Product & Materials Engineering

The gap between a working prototype and a manufacturable product is where most hardware companies lose a year. The prototype was hand-built by the person who designed it, with materials chosen because they were available, and none of that survives contact with a production run.

This unit closes that gap. Mechanical and thermal engineering, because heat is the constraint that quietly limits performance in dense electronics and battery systems. Materials selection and characterisation, including the trade-offs between cost, availability, recyclability and regulatory acceptability. Prototyping and physical test to replace opinion with data. Design for manufacture and assembly, tolerance analysis, and the supplier conversations that follow.

Regulated products carry an additional burden: qualification and test evidence that has to exist in a specific form. Designing against those requirements from the start costs a fraction of retrofitting them after a failed submission.

We work with Product Design on form and use, and with Supply Chain & Procurement when material availability starts driving the design.

Typical mandates: a prototype taken to manufacturable design, a redesign for cost, yield or manufacturability, a materials substitution under regulatory or supply pressure, or failure analysis after field returns.