Product Design and Development

Concept to Production

The heart and soul of Critical Path Design Corporation is my experience in product design and development. The challenge of working an idea through tooling and into manufacturing is a process that Critical Path Design considers its expertise.

As you know, ergonomics, human factors, and product styling are a few of the key elements in a successful product. The feasibility of manufacturing, details of the electro-mechanical design phase, and cost are just as important. "Cost is the thief of a good idea." I've learned that a profitable product is made by staying focused on the design intent and the value that your product will deliver to the consumer.

Because of my project management experience, I understand the importance of keeping all groups involved, including electrical, mechanical, software, sales, and manufacturing. In addition to this, my managerial responsibilities have required a thorough understanding of the sourcing of new components, and UL/FDA guidelines etc.

I'll work with your idea and your team to help you plan and innovate to meet your goal. Throughout the entire project, I will keep detailed records and open communication. Whether the product is one part, such as a dust pan, or consists of hundreds of parts like some types of medical equipment, CPD will help you meet your goals.

Prototyping

Prototyping is a key phase of product design where the 3D cad file(s) is converted to an accurate solid part that will be used for fit, function, testing, and marketing. I have experience and enjoy working with all types of technologies that will quickly make your product a reality. These include SLA, SLS, FDM, Urethane, Cast, and CNC machining. Use of Stereo Lithography (SLA) and Selective Laser Sintering (SLS) is very common because these processes allow parts to be built exactly as designed in a matter of hours.

As shown to the right, several parts made out of SLA material from the 3D files were used successfully to assemble the customer's product, and to gain their approval for production molds.

Testing

Once prototypes are received, whether mechanical or electrical, I will fully support the testing and documentation process. Fit, form, and function will be checked, and files updated. To eliminate costly changes, this needs to be done before tooling. Many companies I work with give the prototypes to focus groups, targeted by sales, to gain feedback on the product. As a result of this, it is often necessary to implement changes.

Whether testing at the prototype phase, or prior to manufacturing, CPD supports the process as needed. Keep in mind that designing test fixtures is not uncommon, and is part of the service I provide.

Tooling Phase

To save you time and money on unnecessary mistakes during this phase, I follow the 3D CAD data through the entire process, and keep accurately detailed features in the file. At Critical Path Design I take pride in working out the tough details that insure a successful product. These elements such as draft, rounds, part thickness,
and materials are critical factors in the development of your part or product.

I will provide tooling support for you at home or in Asia as needed. I have experience with inspecting first article parts and having them re-worked until they meet production quality. CPD has worked with several processes, including injection molding, blow molding, rotational molding, stamping, vacuum forming, and extrusions.

Manufacturing Support

Once your molds/tools are completed and the parts are being efficiently produced, I will follow through with any necessary production controlled drawings and fixture designs. (See Production Drawings.)

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