Flexible Projects
Every project follows its own unique path. Instead of a rigid, one-size-fits-all process, I use a flexible framework of stages that can be added, removed or re-ordered to fit the job.
Focused, well-bounded work that can move quickly from a clarified brief to build-ready CAD. Typical examples are creating single parts, reparing legacy CAD, modifying existing parts, or rebuilding from 3D scans. For this work, I can usually quote fixed price, and turnaround is often a matter of days.
Breadth-first exploration to define the right approach. We typically clarify aims and constraints in, generate a wide range of concepts, then select a direction in based on evidence, constraints and acceptance tests. Sometimes, initial de-risking is conducted to increase confidence in the selected design direction.
Goal-driven, empirical work to create rigs, fixtures or lab or industrial equipment. Often, these can involve concept generation through to detailed design, but with less emphasis on supplier engagement, since the device is often not intended for volume manufacture, and therefore may not require detailed handover to production.
End-to-end development for a small, relatively simple product. We shape the brief, explore and select options, and de-risk early with targeted tests so detailed design proceeds with confidence. Manufacturing volumes is a key consideration throughout, and often requires detailed reviews with suppliers and manufacturers. A few prototype passes are typical, and detailed documentation supports a handover to production.
System-level development with multiple subsystems and stakeholders. We invest in clear acceptance tests and evidence-based selection, and de-risk before detailed design. Often, specialists from multiple disciplines are involved. Supplier engagement is critical to confirm manufacturability, cost and lead time. Several prototype passes are typical, with testing and iteration to refine performance and reliability. Handover typically requires detailed documentation to support complex assembly and commisioning.
Flexible by design: we pick the stages that add value to your project and skip those that don't. These outlines are guidelines, not rules.
S1 Clarify
Goal: Agree a well-defined, measurable brief.
Inputs: Client goals, assumptions, constraints, any legacy files or sketches.
Activities: 30-60 min call, assumptions capture, outline success criteria.
Outputs: Concise, documented brief, initial risks, acceptance tests.
Exit: Stakeholders agree the brief is correct enough to proceed.
S2 Explore Concepts
Goal: Generate a broad option set.
Inputs: S1 outputs.
Activities: Concept exploration, morphological analysis, first-order calculations, simple models or sketches.
Outputs: Short concept document with pros, cons, and key uncertainties.
Exit: Multiple viable, reviewable concepts.
S3 Select Concepts
Goal: Choose the most promising design direction.
Inputs: Documented initial concepts.
Activities: Joint review, evaluating concepts against acceptance tests and constraints.
Outputs: Selected concept(s) with clear justification for selection.
Exit: Stakeholders agree with the selection and what must be proven next.
S4 De-risk
Goal: Build confidence that the selected concept is feasible.
Inputs: Selected concept(s) and associated risks.
Activities: Cheapest decisive tests, quick CAD where needed, supplier sanity checks on tricky features. Fail fast if required.
Outputs: Quick prototypes, test notes, go or pivot decision.
Exit: Risks reduced to an acceptable level for detailed design to proceed.
S5 Detailed Design
Goal: Prepare a build-ready definition.
Inputs: Feasible concept.
Activities: Parametric CAD, initial manufacturing drawings, preliminary BOM, preliminary costing.
Outputs: CAD data, drawing set for prototype, costed BOM.
Exit: Definition is sufficient to get firm quotes and place orders.
S6 Supplier Sync and Build Plan
Goal: Confirm manufacturability, cost, and lead time.
Inputs: S5 package.
Activities: RFQs, DFM reviews, assembly reviews, minor design tweaks, place orders.
Outputs: Build plan, updated drawings if needed, lead time commitment from suppliers.
Exit: Orders can be placed with confidence.
S7 Build and Test
Goal: Prove the design in reality.
Inputs: Manufactured and sourced components.
Activities: Assemble, test, document results. Iterate S5 to S7 if needed. If S4 was thorough, revisiting S2 to S3 should be unnecessary.
Outputs: Functional prototype(s), test report, prioritised issues list.
Exit: Performance meets acceptance tests.
S8 Early Production Handover and Support
Goal: Enable reliable production.
Inputs: Converged design and test evidence.
Activities: Release manufacturing data, support supplier onboarding, oversee first builds as needed.
Outputs: Released manufacturing pack, change log, first build support, agreed support window.
Exit: Supplier confirms readiness and first build runs to plan.
Typical briefs
- We inherited non-parametric legacy CAD/drawings and need clean updates.
- We need a 3D scan and a parametric rebuild.
- I've drawn this thing on a napkin, and I need to get it made.
- This part has broken, and is no longer available, and I need a replacement.
- I need to modify this existing part to fit a new assembly.
Typical deliverables
- Physical parts
- Parametric CAD
- Manufacturing drawings
Typical characteristics
- Scope & requirements: Well-defined; creation, updates or modifications to geometry.
- Uncertainty & risk: Low; constraints are clear and solution is straightforward.
- Pricing: A fixed-price quote is often possible.
- Turnaround: Fast (days).
- Collaboration: Usually solo; check-ins with you and suppliers as needed.
- Analysis & calculations: Minimal; tolerance/fit checks where required.
- Prototyping: Manufactured parts are often required.
- Documentation & rationale: Parametric CAD and manufacturing drawings.
Typical briefs
- I need to turn my idea into a prototype to show an investor.
- Can we create some concepts to explore the feasibility of my idea?
- I need some graphics to illustrate my concept.
- I need a detailed concept to get an early quote from a manufacturer.
- I need a visual model of my idea to help with fundraising.
Typical deliverables
- Physical models
- Parametric CAD
- Renderings
- Illustrations
- Concept selection documentation
Typical characteristics
- Scope & requirements: Emerging; intent is clear but details are open.
- Uncertainty & risk: Low to moderate; exploration within a defined envelope.
- Pricing: Fixed-price concept package may be possible when the brief is clear.
- Turnaround: Generally fast (days to weeks).
- Collaboration: Light; mainly with the founder/product owner.
- Analysis & calculations: First-order calculations to support design options.
- Prototyping: Sketch, visual models and physical mock-ups.
- Documentation & rationale: Concepts, renderings, and selection rationale.
Typical briefs
- I need a custom machine to automate this experiment.
- We need a test-rig to de-risk this aspect of a larger project and our main design team doesn't have the bandwidth.
- Our production team is struggling with this aspect of assembly and needs this assembly tooling.
Typical deliverables
- Parametric CAD
- Manufacturing drawings
- Assembly drawings
- Functional prototype
- Ongoing support
Typical characteristics
- Scope & requirements: Technical goal clearly defined; solution space open.
- Uncertainty & risk: Moderate; empirical learning expected.
- Pricing: Typically hourly; fixed-price blocks for well-bounded tasks.
- Turnaround: Weeks to a couple of months, driven by experiments, lead times and complexity.
- Collaboration: Often requires collaboration with scientists/engineers/operators.
- Analysis & calculations: Targeted calculations/measurements to inform design choices.
- Prototyping: Often requires one or more functional rigs with incremental testing.
- Documentation & rationale: Parametric CAD, manufacturing drawings, and design rationale.
Typical briefs
- I need to develop this concept into a manufacturable product.
- Our design team is fully occupied with other projects and we need to progress this concept to beta prototype.
- I need to develop the concept for my Kickstarter campaign into a working device.
Typical deliverables
- Concepts and illustrations
- Detailed design rationale documentation
- Parametric CAD
- Manufacturing drawings
- Assembly drawings
- Working prototype(s)
- Ongoing support
Typical characteristics
- Scope & requirements: Focused scope; single part or small assembly, often purely mechanical.
- Uncertainty & risk: Moderate; depending on complexity and novelty.
- Pricing: Typically hourly with milestone reviews; fixed-price for discrete, well-defined packages.
- Turnaround: Several weeks to a few months, depending on supplier lead times.
- Collaboration: Often requires collaboration with industrial designers, electrical/software engineers, suppliers, and stakeholders.
- Analysis & calculations: Deeper analysis and verification planning as appropriate.
- Prototyping: One or more working prototypes for fit/function.
- Documentation & rationale: Formal design documentation with traceable decisions.
Typical briefs
- I need to turn my idea into a beta prototype, suitable for volume production, to show an investor.
- I need to progress this concept to a beta prototype, ready for handover to our contract manufacturer.
Typical deliverables
- Concepts and illustrations
- Detailed design rationale documentation
- Parametric CAD
- Manufacturing drawings
- Assembly drawings
- Working prototype(s)
- Ongoing support
Typical characteristics
- Scope & requirements: System-level product with multiple subsystems.
- Uncertainty & risk: Higher; often higher complexity.
- Pricing: Typically hourly with milestone reviews; fixed-price for discrete, well-defined packages.
- Turnaround: Multiple months; schedule driven by iteration and supply chain.
- Collaboration: Often requires collaboration with industrial designers, electrical/software engineers, suppliers, and stakeholders.
- Analysis & calculations: Deeper analysis and verification planning as appropriate.
- Prototyping: Several builds across alpha → beta with structured testing.
- Documentation & rationale: Formal design documentation with traceable decisions.