Research + Discovery

The cost of designing and manufacturing a new product can be overwhelming. My in-depth understanding of the end-to-end NPD (New Product Development) process allows me to provide a comprehensive discovery and planning assessment for any consumer product idea your business may have. This ensures you maximize your ROI while delivering compelling and successful products within your time and budget constraints.

Research – State of the Market, Target Audience Analysis, Key Competitor Analysis, Industry Trend Insights

Idea Generation – Facilitation of Idea Generation and Idea Screening within the framework of business objectives

Product Strategy and Business Case Development – Project Goals and Objective Setting, Research Insights and Analysis Report, Project Parameters and Roadmap Development, Risk Identification, Project Cost and Resource Impact Assessment, Sourcing / Manufacturing Identification and Feasibility Analysis, Price modelling (target RRP and Margin expectation), Go to Market Expectations, IP Protection IdentificationMauris id fermentum nulla. Donec ac fringilla turpis.

Conceptual Design

An exciting and collaborative design process where we transform your ideas into reality through visually engaging sketches, renders, and low-fidelity prototypes. My approach involves generating and refining multiple concepts that balance functionality, aesthetics, and manufacturability. We’ll delve into colour, material, and finish exploration, ensuring that each concept is evaluated and iterated based on user testing and feedback from focus groups. Our goal is establish one or two clearly defined concepts, setting the stage for a seamless transition into the detailed design phase.

Sketching and Rendering – Multiple concepts come to life through sketches and renders

Lo-fi Prototype Creation - Quick iterative mock-ups for proof of concept

Colour, Material and Finish exploration – Market trends, Colour studies, Materials swatch and finish studies, mood-board compilation
Human interaction studies – Understanding how people engage with products, systems and environments, Ergonomic and anthropometric analysis

User analysis and validation –  Feedback generating workshops and prototype testing

Design

A meticulous and detailed design phase transforms concepts into tangible, manufacturable products. Your ideas are brought to life through 3D CAD models, prototypes, and samples. Each prototype undergoes testing and iteration for performance, aesthetics, usability, and safety, with each revision building on the insights from the previous one. Whether it be injection moulded hard goods, or high quality sewn goods I’ll ensure we consider and specify the finest details necessary to achieve a high quality functional product.

Product Concept Development – Feature development

Colour + Aesthetic Studies and Development

2D Renders and detailed drawings – development of construction details, features and initial specifications

3D CAD Model Development – 3D Engineering drawing development

Tech Pack development – Document creation for soft good development

Prototype Creation – detailed samples and prototypes (3D prints)

Development

A comprehensive process for realizing your design and preparing it for manufacture consists of several key stages, ensuring a smooth transition from concept to production. We start with detailed design and engineering to develop and refine product features, ensuring that your vision is accurately captured. Next, we conduct manufacturing feasibility and design-for-manufacture studies to optimize every aspect of the product. We confirm specifications and finalise production processes while meticulously crafting cost models to keep the project within budget. To mitigate risk, we implement thorough verification testing and Failure Mode and Effects Analysis (FMEA).

Finally, I complete all necessary production documentation and release it to the manufacturing vendor, ensuring a seamless handover for production.

Supplier Liaison – Introductions, Discussion on feasibility, scope and costs

Design for Manufacture – Material selection, Process compatibility, Manufacturability, Cost and Production Efficiency Analysis

Product design and engineering – Detailed Design and CAD Engineering
Design Verification Testing – Prototype and sample verification and validation testing
FMEA – Risk mitigation, Failure mode and effects analysis
Production documentation release  – Finalisation of production documentation

Manufacturing Consultation

Ensure your product meets top standards with my comprehensive manufacturing consultation. Starting with off-tool sample inspection, testing, and "Golden Sample" creation, I’ll work with you to define a high benchmark for pre-production approval. We'll set up robust quality control measures, including inline tests and custom test jigs for efficient, repeatable checks. I also guide you through regulatory compliance, ensuring industry-required testing for safety and legal standards. With my support, you’ll bring a reliable, compliant product confidently to market.

Off-tool samples inspection, testing + verification – assessment of off tool samples and optimisation for Golden Sample (Pre-production) sign off

Quality Control Measures – Establishment of QC requirements and inline test procedures

Test Jig Development – Design and development of inline production test jigs and procedures for QC procedures

Regulatory Compliance –Assistance with regulatory compliance testing

Packaging Design

A comprehensive packaging design and development service that begins with defining the Purpose and Objectives—addressing protection requirements, differentiating between e-commerce and retail needs, and aligning packaging goals with marketing, branding, and technical demands. Through in-depth Market Research, we’ll analyse competitors, industry trends, target audiences, and compliance standards while balancing cost targets. The process moves into Concept Development, where we visualize 3-4 design options through sketches, digital mock-ups, and lo-fi prototypes, exploring materials, shapes, and structural needs. In the Detailed Design phase, we create CAD models, develop dielines, test prototypes for product fit, and evaluate user experience through unboxing and drop tests. I also provide Graphic Design services, ensuring the visual composition—logos, colour palettes, typography, and imagery—aligns with brand identity and labelling compliance. The final phase includes Sampling and Evaluation, where we develop and test final samples for durability and compliance, perform cost analysis, and finalize golden samples for production sign-off.

Define Purpose and Objective – Define Protection requirements, e-com vs retail facing, marketing and branding. Define, goals, technical requirements, timelines and budgets

Market Research – Competitor analysis, trends, target audience, compliance and industry standards, Cost targets

Concept Development – Visualise designs through sketches, digital mock-ups and lo-fi prototypes for 3-4 different options. Explore materials, shapes and structural requirements

Detailed Design – Structural design in CAD and dieline development, detailed prototyping, product fit check, user experience “unboxing tests” and drop testing

Graphic Design – Design visual composition, logos, colour palette, typography, imagery. Incorporate brand identity and ensure labelling compliance.

Final sampling and evaluation – Final sample development, final durability and compliance tests and checks, Final cost analysis. Golden sample sign off