A visual explanation of the processes used by EnCata in the production and promotion of a hardware product through the TRL system. The process starts with an idea and includes many steps, including multiple estimations, prototyping (alpha and beta), quality control, certification and more.

1. Process explained

2. Analysis /
Definition
Is there a market
product/customer
research made?
Technical
discovery
Detailed
Request for
Proposal (RFP)
New
product
Engineering
(sub)system
development
Statement of Work
(SoW) for POC or
alpha-prototype
Development
Request
Yes
No
Estimate-1Estimate-0
Estimate-0
Estimate accuracy
Estimate-1
Estimate-2
-75% ... +400%
-50% ... +300%
-25% ... +75%
Estimate-3
Pre-Development phase
-10% ... +25%

3. TRL-8 prototype
development and
DFM optimisation
Passed beta tests Batch manufacturing
10-100 pieces for β-tests
with customers
Prototype
qualified as
TRL-7
Passed
field tests
Not
Passed
Further
prototype
development
Verified and
updated CAD +
documentation
Prototype full CAD
and non-verified
documentation
Detailed CAD for
subsystem or POC
POC Subsystem
prototype/mockup/
crude prototype
Tests
Is there a critical
subsystems?
Yes
No
Preliminary
BOM
Design
Estimate-2
(DE-2)
Time/Budget
Design
Estimate-1
(if needed)
Manufacturing
Estimate-1 (ME-1)
BOM
Estimate
Statement of
Work (SOW)
Field
Tests
Internal
Tests
TRL-6 prototype
manufacturing
Product CAD +
α-prototype
documentation
development
Technical Concept
development with
preliminary CAD for
prototype
Technical
Discovery
Analysis/
Definition
phase
R&D
Pr o t o t y p e
D e v e l o p m e n t
p r o c e s s

4. Design
Estimate-3
BOM
Re-Estimate
Manufacturing
Estimate-3
(ME-3)
Tooling
Design
Estimate
Sales
Tooling
manufacturing
First batch
manufacturing
Tooling
Design
Verified and updated
CAD + documentation
for TRL-8 Tooling CAD and
documentation
Updated tooling
documentation
Prototype CAD optimisation
for mass-production (DFM)
TRL-8 prototype
development and
DFM optimisation
production launch process

5. Client side
PM
on CLIENTS side
Our PMs typically have a PhD and
take the active role in product
development, acting as a BA/PM
Project Phase Engineers involved
Prototype
manufacturing
Software
development
Analysis
Technical
Discovery
Development
and Prototyping
BA(s) (business analyst(s)
Lead mech. Engineer
Lead mech. Engineer
Lead electronics engineer
Lead electronics engineer
Procurement engineer
Procurement engineer
Mechanical engineer
Manufacturing team
Manufacturing engineer
Industrial designer
UX designer
Mech. engineering team
Electronics engineering team
BA
UX/UI designer
Development team
QA team
Embedded software engineer(s)
Manufacturing engineer
“Core Technology”
Expert, Scientist
CTO
CEO
Key Decisions
Project execution and
communication interface
1
Option 1
Dedicated
Team
2
Option 2
Agile Development
Team (T+M)
Product Owner

6. 1 2 3 4 5
Definition/Analysis
Technical Discovery
Development
and Prototyping
Tests
Finalization = TRL-8
Problem definition,
solution, user stories,
development objectives
Specification dev., technical benchmarking,
form and function technical concepting,
TRIZ, detailed development strategy
for parts and [sub]system
(design-for manufacturing,
engineering validation tests,
certification, batch production)
1. Requirements
discovery
2. Requirements
classification and
organization
R&D
3. Requirements
prioritization and
negotiation
4. Requirements
specification
TRL-X Prototype
Further
development
and changes
TRL-5: subsystems are designed and working as required
TRL-4: Proof-of-Principle prototype / demonstrator
TRL-6: a good looking “polished” α-prototype
TRL-7: the α-prototype has passed “field tests” and is working
EnDevelopment process practiced in Cata

7. TRL 1-2 TRL 3-7 TRL 8 TRL 9
Definition Discovery
Validate
Specifications
Identify IP needs and
Tech. Restrictions
Form and
Function
Concepting
Technical Concept
Development
1 Production52 Prototyping3 Finalization4
Solution
User stories
Objectives
Product
Objectives
Development
strategy
Proof-of-principle
Prototype
Alpha-prototype
Beta-prototype
Production
Ready Design
Product Ready
for market
Design
Build
Test
Problem
Management
Tooling Design
Quality control
and support
Sample Inspection
Design for
manufacture
Vendor Sourcing
Engineering
Validation Testing
Patents filling
Certifications
Estimate-0 Estimate-1 Estimate-2 Estimate-3 Estimate-4
Hardware Development Process Overview

8. Boston
+1-857-302-4299
Suhar
+968 99 41 13 08
Prague
+420 (77) 483-94-19
Brussels
+32-475-30-90-87
Minsk (HQ)
+375(44) 472-50-31Tallinn and Riga
+371 (29) 21-93-16
+372 (58) 86-84-07
Dr. Peter Dudin
p.dudin_work | pd@encata.net
encata.net
+375-(44)-472-50-31
Partner. Head of
business development
challenge
Do you have a
to solve?