Bringing a new product to market requires more than just a good idea. It takes a rigorous, manufacturing-driven development process that ensures your product is functional, manufacturable, and scalable. Too often, a product development company will focus heavily on the front-end innovation while overlooking the realities of production, leading to delays, cost overruns, or failed launches.
The product development and manufacturing process
At Synectic Product Development, we bridge the gap between concept and production by integrating engineering, prototyping, and manufacturing support into every stage of development. Our process prioritizes our dfm services, risk mitigation through FMEA, and material and process selection to streamline the transition from design to mass production, so you can get to market faster, with less risk and higher quality.
We follow a structured product development and manufacturing approach designed to minimize risk, reduce costs, and optimize for scalable production. Unlike siloed development models, our process integrates design and manufacturing considerations from day one, saving you time and money.
1. Concept generation and feasibility
Every product begins with a problem to solve. In the concept phase, we work closely with you to clarify your product’s goals, user needs, and performance requirements. We start by conducting background research to understand competitive products, market trends, regulatory requirements, and technical feasibility.
Once we define the product scope, our team generates manufacturing-focused early concepts using sketches and CAD models. For example, we evaluate if the part can be molded, machined, or assembled efficiently. We also identify any early red flags, such as overly complex geometries, tight tolerances, or material incompatibilities, that could create issues later in the production phase.
By the end of this phase, you’ll have a solid design direction backed by real-world data and a clear understanding of what’s technically possible, economically viable, and aligned with your business goals.
2. Design engineering and DFM
The design engineering phase is where your idea becomes a fully defined product. Our multidisciplinary engineering team works together to build detailed 3D models, select critical components, and create a functional design architecture. While innovation is a priority, manufacturability is non-negotiable.
From the beginning, we apply design for manufacturability principles by optimizing wall thickness, reducing unnecessary part count, and simplifying assembly steps wherever possible. These features cut down on cost and improve reliability and repeatability during production. If you plan to use injection molding, we design with draft angles, uniform wall thickness, and gating strategies in mind.
We also conduct a preliminary DFMEA during this phase. This structured risk assessment allows us to anticipate potential points of failure in the product and proactively address them. It’s especially important for regulated industries like medical or aerospace, where reliability is mission-critical.
We also begin material and process selection, evaluating candidates based on cost, availability, performance, and compliance. Whether you’re choosing between ABS and polycarbonate or deciding on metal forming vs. CNC machining, we guide you toward options that support both function and manufacturability.
3. Prototyping, testing, and validation
Once the design is engineered and reviewed, it’s time to build and test. We fabricate a series of prototypes using in-house manufacturing methods such as SLA 3D printing, CNC machining, and urethane casting for early-stage molded parts.
These prototypes serve multiple purposes: proof-of-concept, form/fit testing, functional validation, and user feedback. For example, you might start with an appearance model to secure investor buy-in, then move to an engineering prototype for mechanical testing. We also build pilot units that simulate early production runs to uncover real-world manufacturing challenges.
All builds undergo a range of testing activities, including drop tests, environmental stress testing, usability trials, and performance verification. This phase is iterative, so issues identified here inform design updates that make the product more robust and production-ready.
We also revisit the DFMEA, finalize risk mitigation strategies, and begin preparing regulatory documentation if needed. The goal is to move into manufacturing with a thoroughly validated design, minimizing late-stage surprises that derail production timelines.
4. Manufacturing transfer and production support
Transitioning from prototype to production is one of the most complex and failure-prone stages of product development, but it’s also where Synectic provides the most value. We support full-scale manufacturing transfer within the Mack Group, helping you move from final design to real-world production with confidence.
This includes preparing complete manufacturing documentation: detailed 2D drawings, exploded views, Bills of Materials (BOMs), assembly instructions, test protocols, and packaging specs. We assist in identifying and qualifying vendors for components and subassemblies, considering cost, lead time, and geographic location.
We build pilot builds and low-volume runs that allow you to test your manufacturing process at scale in our in-house new product introduction space. These early builds often surface last-minute adjustments needed for tooling, tolerances, or assembly flow. For larger builds, we transfer your product to our parent company, Mack Molding. With several manufacturing facilities in the United States, we can offer contract manufacturing services for any product size and production volume.
Even post-launch, our team works closely with Mack Molding, providing engineering and manufacturing support as needed. If you’re ramping up production, planning a revision, or looking to reduce costs over time, we help optimize the design and processes accordingly.
If you’re looking for a product development company that thinks like a manufacturer, Synectic is ready to help. Our end-to-end process ensures your product is ready for the real world. Contact us below to discuss your next product development and manufacturing project.
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About Synectic Product Development: Synectic Product Development is an ISO 13485 certified, full-scale product development company. Vertically integrated within the Mack Group, our capabilities allow us to take your design from concept to production. With over 40 years of experience in design, development, and manufacturing, we strive for ingenuity, cost-effectiveness, and aesthetics in our designs.
