New Product Introduction

Launch your new product the right way

Our brand-new controlled manufacturing environment is one of the exciting capabilities now possible through our new facility in Woodbridge, CT. Able to be customized for different production line layouts, we have the perfect space for products starting the journey into full scale manufacturing. Through our new product introduction process, your invention can be introduced to the market efficiently and cost-effectively, before making its way into full scale production.  

New product introduction is the first step in the process of transferring your product design into a full scale manufactured product. The NPI space offers a controlled manufacturing environment to debug and fine tune the manufacturing process before it becomes cost prohibitive later in the manufacturing and assembly process.  This critical step is a low cost solution to mitigating risk early. Our goal during this times is to successfully test out the manufacturing and assembly processes and strategy before transferring to pilot or contract manufacturing. By fine tuning and optimizing the process at this step we are able to identify and eliminate issues that could arise during lot builds. If you were to skip this critical step and head from DFM/DFA straight into full scale production, you would find yourself wasting more time, money, and effort to correct processes and strategies that are now under manufacturing control. 

contract manufacturing clean room

Design For Manufacturing / Design For Assembly

Once phase 3 of the product development process is complete, your prototype design then moves into our NPI area for the beginning of phase 4, design for manufacturing (DFM) / design for assembly (DFA). During this phase each component will be designed for optimal fabrication and cost. Unlike the previous three phases, the beginning of phase 4 takes place mostly behind the scenes. Unlike the previous three phases, the beginning of Phase 4 consists mostly of design and documentation activities.  Each step in this part of the process is crucial to ensure you have a manufacturable end product.

Bring Your Design To Life

Pilot Manufacturing

This phase of the NPI process can be broken up into three main parts: documentation, building, and testing.

Pilot manufacturing requires a large amount of documentation focused primarily around quality checks. More paperwork occurs during this phase than any other. Every part and process needs to be cataloged and traceable. If your project is a medical device, even more documentation may be required based on what you will need to pass FDA inspection. Depending on where you are in the process, certain documents are not easily changed so accuracy and communication between parties is key.

Several lots of units will be built at various points during the pilot manufacturing phase to be used in debugging both the assembly and manufacturing process. Packaging will be also be designed and built. The units that are produced during this process are not sellable, but are primarily used as demo units in the field.

This is where everything and anything that goes into producing your product is tested. The units and packaging are tested to ensure they can withstand normal wear and tear, shipping, handling, and, in the case of medical devices, sterilization. The assembly and manufacturing processes are also tested to make sure the build is accurately repeatable. 

Get Your New Product Started

Pilot Production

This is the final part of the journey your product will take through our NPI area, before heading to full-scale contract manufacturing. The units that are produced during these builds are tested against real-world scenarios to ensure a safe working product at the end of the manufacturing process. Best of all, the units produced out of this part of the process are traceable and sellable.