our process

Discovery

Free initial consultation
Product audits
Competitive analysis
Research

Specification

Technology audits
Product specification
Route to market analysis
Product planning roadmap

Design

Product and roadmap definition
Ideation
Product experience map
Space envelope definition
Concept design

Design Engineering

Component layout review
Space envelope CAD
Manufacturing analysis
3D CAD development
Regulatory review

Optimisation

Product review
Design for manufacture + assembly
Design for serviceability
2D drawings
QC process level review

Realise the Product

Tooloing review
Debug reports
Production process development
BOM Management
Documentation
Supplier sourcing and review

Discovery

Boxclever don’t charge for the initial meeting where we discuss working together – What will excite the user? What problems need to be solved? What is the best path to production? – These will all be discussed at the initial meeting. Boxclever has a team experienced in all facets of the design process, and can balance all of the critical factors unique to each project. Leveraging our expertise, issues such as budgets and how they affect timescales and final product cost will be discussed.

Specification

Boxclever can work from a well-defined specification, but what often happens is that we are asked to input and build the specification with the client. Research is carried out in this stage using multiple tools and processes to gather information and focus the later development stages. Risks are minimised, and an in-depth understanding of the design road map is put in place.

Deliverable: Specification, project plan, research reports.

Design

Form, aesthetics, user needs, ergonomics, manufacturing processes (and the different cost for each process) are all considered by the industrial designer during concept design. All of the research in the definition stage is distilled into coherent design concepts. A number of concepts are chosen for development in 3D CAD, and are rendered as photo-realistic images. Sketch models, hand formed in foam, or 3D printed may be used to test ergonomics. Our knowledge of the full design/manufacturing process means that any of the concepts can be brought to production while maintaining the original design intent.

Deliverable: Multiple, fully rendered concepts.

Design Engineering

Boxclever excel technically. We have designed high volume products that sell millions every year, and batch production products which sell one hundred a year. These are engineered differently, and use different production process. The chosen concept is developed in 3D CAD based on the knowledge of DfM (Design for Manufacturability), DfA (Design for Assembly) and DfX (Design for Quality, Serviceability, Sustainability, ReUse, Cost). These tools will be used to systematically drive the design. During the engineering stage any certification / testing specifications will be reviewed for adherence. Boxclever has a list of audited suppliers, both in Europe and Asia. The route to production will be discussed and 3D CAD sent for quotation at the same time as the final prototype is produced.

Deliverable: 3D CAD for prototyping, analysis/review reports, quotations.

Optimisation

Prototype products are built to verify the design and assembly methodology. The prototypes can be reviewed within the engineering team, or multiple prototypes can be user-reviewed. Any changes or enhancements to the design can be implemented. Packaging can be reviewed at this stage. Before releasing to the chosen supplier, tooling design detail will be discussed to ensure reliability and stability of the tools and the parts produced. A release package is created including 3D CAD, CMF details, QC documentation and 2D drawings.

Deliverable: Production intent 3D CAD, documentation package.

Realise the Product

Boxclever has built up an expertise is transferring a product from design to production. We have worked with suppliers globally to ensure a smooth, fast transfer, whether it be for enclosure parts only, or full assemblies. We offer an open book policy for our database of sourced, audited suppliers; clients can deal direct from day one. Working with the supplier and client, the product is reviewed, verified and validated.

Deliverable: Signed-off, off process parts/assemblies.