1. 1Proprietary and Confidential, techHousedesign
Designed to Scale:
A Framework for Effective Product Design and Design for Manufacturing
2. 2Proprietary and Confidential, techHousedesign
○ I am a Designer and Engineer who
has spent the last 20 years creating
consumer products for mass
manufacturing.
○ I represent the design thinking and
manufacturing resources needed to
imagine and bring an innovative
idea to market.
○ I enjoy helping people make new
things
○ I work without a net
Me
7. 7Proprietary and Confidential, techHousedesign
Governing
Principles
● create products that people want in their life
● make them of the highest possible quality
● produce only only enough to fulfill the need
● use fewer resources in the process
11. 11Proprietary and Confidential, techHousedesign
I. Concept Generation
II. Product Development
III. Design for Manufacturing & Sourcing
IV. Manufacturing & Scaling
Process
17. 17Proprietary and Confidential, techHousedesign
Ibn al-Haytham
965-1040
1. Observation of the natural world
2. Stating a definite problem
3. Formulating a robust hypothesis
4. Test the hypothesis through experimentation
5. Assess and analyze the results
6. Interpret the data and draw conclusions
7. Publish the findings
Or... the Scientific Method.
18. 18Proprietary and Confidential, techHousedesign
Research
Define
Ideate
EvaluateSelect
Prototype Refine
Still the Design Process.
19. 19Proprietary and Confidential, techHousedesign
Divergent / Convergent
Research
Define
Ideate
EvaluateSelect
Prototype Refine
20. 20Proprietary and Confidential, techHousedesign
Presented at Visualized Conference on 11.08.2012 at the Times Center in New York City.
By: Benjamin Wiederkehr, editor of Editor at Datavisualization.ch
Design Visualized
32. 32Proprietary and Confidential, techHousedesign
Research ethnography
https://www.slideshare.net/chiatlanta/ethnographic-research-for-design-innovation-3578305
observing behavior in natural settings
33. 33Proprietary and Confidential, techHousedesign
Research ethnography
● Takes place “in the field”
● Observation is primary data
collection technique.
● Interviews are used to clarify
observations.
● Attention is paid to context and
artifacts.
● Field notes coded and analyzed
for themes and variables.
https://www.slideshare.net/chiatlanta/ethnographic-research-for-design-innovation-3578305
observing behavior in natural settings
40. 40Proprietary and Confidential, techHousedesign
Research
Define
Ideate
brainstorming
The Rules of Improv.
1. always agree
2. yes and...
3. be part of the
solution
4. there are no bad
ideas
follow the rules of improvisation
create a narrative
consider more than one point of view
don’t stop at your first good idea
46. 46Proprietary and Confidential, techHousedesign
Research
Define
Ideate
Select
Prototype
STRATEGY IDEATION PROOF OF
CONCEPT
DESIGN PRODUCTION SALES
new product birth cycle
47. 47Proprietary and Confidential, techHousedesign
Research
Define
Ideate
Select
Prototype
STRATEGY
Prototyping strategy
simulationsservice blueprintbusiness plan
find and understand opportunity before investing in it
48. 48Proprietary and Confidential, techHousedesign
IDEATION
Research
Define
Ideate
Select
Prototype
Prototyping ideas
thought
experiments
quick modelssketches
communicate your concept through a visualization
renderings
49. 49Proprietary and Confidential, techHousedesign
PROOF OF
CONCEPT
Research
Define
Ideate
Select
Prototype
prove it works, don’t worry about scale.
Prototyping a proof of concept
breadboardfrankenstein rapid prototype
50. 50Proprietary and Confidential, techHousedesign
DESIGN
Research
Define
Ideate
Select
Prototype
developing new
methods
ergonomic studies functional tests
Prototyping your designs!
51. 51Proprietary and Confidential, techHousedesign
PRODUCTION
Research
Define
Ideate
Select
Prototype
pilot productionCAD / DWG molding simulation
Prototyping production
now is your last chance to get it right
52. 52Proprietary and Confidential, techHousedesign
SALES
Research
Define
Ideate
Select
Prototype Prototyping Sales
Presales & Crowdfunding Search Market ValidationStraw Product Sales
starting at the end
53. 53Proprietary and Confidential, techHousedesign
Research
Define
Ideate
Select
Prototype
$
cost of a
design
change
time
Why do we do it?
61. 61Proprietary and Confidential, techHousedesign
What’s a patent worth?
IP Tactics
from: Mechanical Engineering for Hackers by Will McLeod
62. 62Proprietary and Confidential, techHousedesign
Producing in Scale
Quantities 1-10 10-100 100-1000 (MOQ) MOQ+
Service Level design proof
hand testing
ergonomic studies
photography
life testing
promotional items
light duty products
short term user testing
low volume production mass production
Plastics CNC
FDM
SLS
polyjet
laser cut
CNC
FDM bot farm
SLS
proto-mold
urethane casting
extrusion molding
CNC
SLS
proto-mold
extrusion molding
injection molding
compression molding
proto-mold (<50k)
injection molding
extrusion molding
compression molding
blow molding
2K molding
Metals investment cast
CNC
Hand Machining
sheet metal
welded steel
laser cut
investment cast
CNC
Hand Machining
sheet metal
welded steel
laser cut
investment cast
CNC
sheet metal
welded steel
die cut
laser cut
investment cast
CNC
sheet metal
die cast
forged
stamped / drawn / spun
63. 63Proprietary and Confidential, techHousedesign
The Uncanny Valley of Production
Quantities 1-10 10-100 100-1000 (-MOQ) MOQ+
Service Level design proof
hand testing
ergonomic studies
photography
life testing
promotional items
light duty products
short term user testing
low volume production mass production
Plastics CNC
FDM
SLS
polyjet
laser cut
CNC
FDM bot farm
SLS
proto-mold
urethane casting
extrusion molding
CNC
SLS
proto-mold
extrusion molding
injection molding
compression molding
proto-mold (<50k)
injection molding
extrusion molding
compression molding
blow molding
2K molding
Metals investment cast
CNC
Hand Machining
sheet metal
welded steel
laser cut
investment cast
CNC
Hand Machining
sheet metal
welded steel
laser cut
investment cast
CNC
sheet metal
welded steel
die cut
laser cut
investment cast
CNC
sheet metal
die cast
forged
stamped / drawn / spun
64. 64Proprietary and Confidential, techHousedesign
Some obvious Cost Drivers
Plastic:
● quantities
quantity goes up, $ goes down.
● part size
large parts mean large molds
● wall thickness
you pay by weight
● mold complications
lifters, undercuts, threads
● material
by decreasing $
PA
PC / Tritan
ABS / PMMA / PS
PET
PP / PE
Metal:
● part shape
large sizes and complicated shapes
● operations
every action requires a tool
● material
stainless grades
steel grades
● finishing
polishing costs
65. 65Proprietary and Confidential, techHousedesign
Some not so Obvious Cost Drivers
Plastic:
● part shape
can affect tooling
● wall thickness
increased molding time,
decreased capacity
● colors
1 tool per color
● materials
1 tool per material
Metal:
● part shape
you pay for your scrap
● operations
some actions require more than one tool
● material
some are easier than others
● finishing
non-stick, anti-oxide, color, shine
brushing costs more!
● heat treatment
for hardness or temper
68. 68Proprietary and Confidential, techHousedesign
Talking to suppliers
● Prepare an NDA
● Have a drawing or spec.
● Know your production quantities.
● Be specific about your tolerances, materials, and
finishes.
● Get your units right.
● Ask about sampling fees and NRE’s.
● Don’t forget about lead times and shipping!
69. 69Proprietary and Confidential, techHousedesign
Make drawings and BOM’s
It will make your life easier and US Suppliers will ask you for them.
70. 70Proprietary and Confidential, techHousedesign
Even pictures if you have them..
or colour samples...
materials and
textures too!
72. 72Proprietary and Confidential, techHousedesign
Where to look
what is your priority?
● close to me
● my customers
● raw materials
● regional expertise
● made in the U.S.A.
73. 73Proprietary and Confidential, techHousedesign
manufacturing clusters
follow the money
https://www.wired.com/2011/05/ff_jobsclustermap/
80. 80Proprietary and Confidential, techHousedesign
BEFORE CLICKING
know exactly what you need. ● A specific part:
part number, part name
● Industry specific terms
● Regional requirements:
threads (inch metric), AC voltage
● Process requirements:
batch size and NRE’s
understand what’s possible,
know your tolerances, by process and industry
● Material:
grade and quality, finishing,
special handling, food safety
● Quantities and lead times
● Regulatory needs
87. 87Proprietary and Confidential, techHousedesign
Consider a Manufacturing Contract
a few details:
● Manufacture and Supply of the Goods
● Payment of Price
● Late Payment and Interest
● Quality of the Products
● Intellectual Property and Trademarks
● Duration and Termination
● Consequences of Termination
● Confidentiality
● Dispute Resolution