Product Startup Podcast Episode 203: Design for Manufacturing for New Products

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Guest: Paul Davis, Senior Industrial Designer at TriMech Design Solutions, formerly MAKO, with nearly 10 years on the team.

Host: , founder of Product Startup and the leading expert in hardware startup consulting. A hardware entrepreneur since 1999, Kevin has advised more than 1,500 founders and built and scaled MAKO Invent through its acquisition by TriMech in 2024.

Episode Overview

Paul Davis explains the difference between basic CAD and designing a product with manufacturing in mind from the outset. The episode covers part simplicity, draft angles, tooling, OEM components, material data, and the close relationship between industrial design and conceptual mechanical engineering.

Podcast cover for Episode 203: Design for Manufacturing for New Products

What You’ll Learn in This Episode

  • Designing products for manufacturing.
  • Cost-effective, good-looking, and high-quality is best!
  • Concept design needs to take into account planning, parts, and logic for how the product will eventually be manufactured.
  • Simplicity in design leads to quality manufacturing.
  • Using manufacturing CAD software to build original CAD models heavily improves the process and reduces costs in both prototyping and manufacturing.
  • Considering how you manufacture your product while building your first full CAD design is integral.
  • There are many manufacturing methods that go into developing a new hardware product.
  • Manufacturing draft angles, tool design, part integration, OEM parts, materials data sets, etc.
  • Industrial design and conceptual mechanical engineering are interconnected.
  • Simple products succeed more often than complex products for new hardware startups developing a new invention idea for the first time for manufacturing.

Episode transcript

This transcript is provided for accessibility and reference. Download the SRT transcript.

Read the full episode transcript

Kevin Mako: Hello, product innovators. Today we learned the importance of doing CAD design and a design for manufacturing method from a senior industrial design expert.

Kevin Mako: This is the Product Startup Podcast, a show to learn from top leaders in hardware product development, prototyping, manufacturing, product selling, and everything in between.

Kevin Mako: Hosted by Kevin Mako, the leading expert on product development for hardware startups.

Kevin Mako: Welcome back, everyone. Today I'm very excited to introduce Paul Davis to the show.

Kevin Mako: Paul is a senior industrial designer at our very own Mako Design for almost 10 years.

Kevin Mako: He achieved Honours status in his degree in product design engineering and industrial design at the

Kevin Mako: University of Edinburgh. Today, Paul is going to share some valuable knowledge for inventors,

Kevin Mako: startups, and small manufacturers on the difference between basic CAD and design for manufacturing.

Kevin Mako: Why it's so important to do design for manufacturing from the beginning of the design process

Kevin Mako: and best practices to designing a great product to be producible and be a big success in the market.

Kevin Mako: Now on to the episode.

Kevin Mako: This show is produced by Mako Design.

Kevin Mako: original firm providing end-to-end consumer product development services tailored specifically

Kevin Mako: to hardware startups, small manufacturers, and inventors. Take your product from idea to store shelves

Kevin Mako: at MakoDesign.com. Now on to the episode. Hey, Paul, welcome to the show.

Paul Davis: Thanks for having

Paul Davis: me on.

Kevin Mako: I'm excited to have you on the show today to talk about design for manufacturing,

Kevin Mako: why it's so important, not just a major differentiation between just regular designing a product idea

Kevin Mako: versus designing specifically for manufacturing a product, but why it's so important

Kevin Mako: to be considering and building in, planning for, and doing design for manufacturing early in

Kevin Mako: the industrial design process for a new hardware product. Before we jump into all that,

Kevin Mako: Paul, just give us a bit of a background of how you got to the success that you are today.

Paul Davis: Yeah, absolutely. So I graduated from Edinburgh and Napier University for the design,

Paul Davis: and there was also the engineering side as well. So not only were we designing to make something

Paul Davis: to look clean, sexy, and appealing for the market. We also understood the engineering

Paul Davis: behind it, how it's going to be made. The materials you need to use to get to market and ensuring things

Paul Davis: are cost-effective to make. Combining those two skill sets made a very useful degree,

Paul Davis: I had the privilege in Switzerland where I specialized in working on prototype design and figuring

Paul Davis: out the nuts and bolts before working on designing for production. So that was kind of my

Paul Davis: degree before I moved to Toronto in 2012.

Paul Davis: where I did a six-month internship at Mako before I got hired.

Paul Davis: So here we're at today.

Kevin Mako: Yeah, almost 10 years later, worked on countless amount of products, dozens upon dozens that

Kevin Mako: are on the shelves that people can buy today at major retailers, on Amazon, you name it.

Kevin Mako: Paul's name is behind many of these that you see on the shelves behind me, actually, and obviously

Kevin Mako: many that are in the Mako showrooms and so on across our studios.

Kevin Mako: So today, I really want to talk about the importance of those early stages.

Kevin Mako: of design. This is a really critical juncture. A lot of the time it's something, especially

Kevin Mako: non-technical hardware founders, don't really put a lot of emphasis on or understand the importance of

Kevin Mako: the early ideation and design phases, although it may seem relatively simple or, and likely is

Kevin Mako: relatively lower costs than maybe some of the more hardcore engineering and prototyping subsequent phases,

Kevin Mako: the reality behind that is this is arguably your most important phase. This is the entire platform,

Kevin Mako: the infrastructure, the base of everything that you do going forward.

Kevin Mako: Not only can it ensure that your design is great, not only can it ensure that your design is

Kevin Mako: manufacturable, but it will save you a lot of money as well in the development process if

Kevin Mako: you build it correctly from the beginning.

Kevin Mako: So, Paul, talk a bit about what the difference is between just roughing up some 3D CAD design

Kevin Mako: versus developing that industrial design and CAD design specifically for manufacturing,

Kevin Mako: traditional design for manufacturing logic.

Paul Davis: Yeah, absolutely. And just to your point that, Kev, like the main reason companies and vendors

Paul Davis: come to Mako for help is they want their products in store shelves. They don't want to paint a pretty

Paul Davis: PDF picture and go, hey, I'm happy now, you know. So our goal is to really, on the early stage of CAD,

Paul Davis: where we're just conceptualizing, here's how we want it to look in the future. This is the main

Paul Davis: goal all the way through to, okay, this product is now manufacturable. We've considered the

Paul Davis: materials. We've considered the surface fitness.

Paul Davis: the textures, how this part is actually going to be physically made.

Paul Davis: When we are working on the early stage concept CAD design, that CAD file, we will use all the way

Paul Davis: through to the final production unit. So talk about that more detail. The concept design is typically just

Paul Davis: this is how it's going to look from an external standpoint. When we move into prototyping rounds,

Paul Davis: we're looking at potentially doing three prototypes, including like a nice, clean, simple

Paul Davis: mock up to get an idea of form factor and how this part could work.

Paul Davis: through to a more mechanical, detailed, pre-production prototype where we're kind of ironed out

Paul Davis: the kinks. We know what this thing is going to feel, the form factor, the ergonomics, the mechanics

Paul Davis: of the part. Pretty much dialed in. From experience, my most successful products on the market

Paul Davis: are the simple ones. They don't have many bells and whistles, which you've probably had in the

Paul Davis: podcast a few times. It's simple to make. They're easy to make. Tooling costs are low. That can get your

Paul Davis: first product off the ground and running. You've highlighted a couple of really important things in there.

Kevin Mako: First of all, designing for simplicity. That is a key element of design for manufacturing

Kevin Mako: and something, again, that is typically overlooked by non-technical founders or first-time founders

Kevin Mako: for hardware startups. When you think of your original product idea, first thing comes to mind

Kevin Mako: as all these bells and whistles and accessories and variety of different features that could be

Kevin Mako: added into the product. But the reality, especially as a hardware startup, is simplicity equal success.

Kevin Mako: So the more that you can factor in reducing features,

Kevin Mako: But focusing on quality of the fewer features that you have, that's how you get a great starting

Kevin Mako: product to market. We talk a lot about MVP on the show, minimum viable product. And it's really

Kevin Mako: important to understand, especially in the hardware space, and which is very different than software,

Kevin Mako: is MVP means that, yes, you've reduced features, but of the fewer features you have,

Kevin Mako: you focus on quality. And that is really instrumental in terms of the design. And that

Kevin Mako: happens all the way back into the original ideation and first

Kevin Mako: CAD modeling that you do. You start obviously with some basic form and structured feature

Kevin Mako: sets, et cetera, that's built through sketching and a variety of other tools and processes that we have

Kevin Mako: in our tool belt to pull the idea onto paper and to make sure that it's a really good product market

Kevin Mako: fit. But when you've got through that portion of it, you start actually building the CAD, you want to be

Kevin Mako: thinking about how you're actually designing that CAD to be a producible product in the end.

Kevin Mako: And that's something as well that you mentioned, Paul. The second thing that I like that you highlighted

Kevin Mako: there is utilizing the software and the technology and the knowledge right from your

Kevin Mako: initial CAD model all the way through to manufacturing, because that is also a big difference. You don't

Kevin Mako: want to start with just roughing up, let's call it computer graphics or computer game software to

Kevin Mako: visualize and interpret your actual 3D model because you're already past that face. Now, when you're

Kevin Mako: building your CAD model, do it right from the beginning. So you build it in global caliber

Kevin Mako: manufacturing CAD software so that the foundation.

Kevin Mako: is strong. And as you go through your prototyping faces, you're tweaking and refining and

Kevin Mako: perfecting that model all the way through to and including production and even including

Kevin Mako: scaling up production. That model is the exact same CAD model, just obviously modified and

Kevin Mako: improved as it goes through these various steps. So, Paul, talk about a few of the actual manufacturing

Kevin Mako: considerations when you're designing the product. I want to get a bit more into the details here in terms

Kevin Mako: of like parts, materials, OEM versus non, custom, et cetera, that sort of stuff that really

Kevin Mako: drives some of that design for manufacturing logic into your original industrial design

Kevin Mako: CAD models.

Paul Davis: Yeah, absolutely.

Paul Davis: And to your point about using the same software from the very beginning, it gives us the

Paul Davis: opportunity to really focus on how this part or product is going to be made from a very early stage.

Paul Davis: We don't have to always go full detail right away, but we do have the ability to be like, okay,

Paul Davis: we can get the dimensions rough then.

Paul Davis: We know exactly how big this.

Paul Davis: part will be considering future manufacturing processes. It doesn't always have to be,

Paul Davis: I call it a blue sky design. This thought, it was engineering fought behind it already from an early stage.

Paul Davis: I always like to tell my clients that we still have to go through prototyping, but we are thinking

Paul Davis: about how this part's going to be made in the future from the get-go. They always kind of feel more

Paul Davis: confident knowing that we're not just painting a PDF is what I usually say. It's like we're

Paul Davis: actually putting thought behind it. And the engineering team that we have on board is the skills across

Paul Davis: the border just with one next level. So we're very, very lucky to have the tools and resources

Paul Davis: on site to do that. So, but to your point, talking more towards what changes need to be made

Paul Davis: moving into CAD. This is where we really get in the nitty-gritty and detailing of the CAD model,

Paul Davis: where it really depends from experience. Typically, I either work alongside that tooling engineer,

Paul Davis: and they'll send the CAD back with the CAD changes that they need made in order to make it suitable

Paul Davis: for manufacturing. So to your point, Kevin, about the manufacturing concept.

Paul Davis: considerations in the early stages of the concept CAD design, we get to the stage where at the end

Paul Davis: of the day, we want this product to be cost-effective to make. Does that mean we have to use off-the-shelf

Paul Davis: parts? Does that mean we have to use a certain material or manufacturing process to achieve that?

Paul Davis: These are the type of mechanical things and manufacturing things we're thinking about from an early

Paul Davis: stage. So I can use our product as an example. We knew this part was going to be injection molded

Paul Davis: from ABS plastic, for example. And we knew that we had the rough end.

Paul Davis: CAD from the original concept. Prototyping CAD was good, but now we have to make an

Paul Davis: injection molding tool for this. How do we do that? We have to consider many factors. Draft angles

Paul Davis: need to be considered when we're talking about injection molded parts. Depending on the size of the

Paul Davis: part or the size of the tool, the draft angle can have an impact on the overall final appearance

Paul Davis: of the part. So we have to consider that from an early stage as well. Is this part interlocking

Paul Davis: into a second piece? We have to look at tolerances. We have to look at how this

Paul Davis: parts going to be fastened through a second piece. So from an early stage, we're considering

Paul Davis: are we using OEM parts? Are we using custom parts? What can we get away with to make sure that

Paul Davis: we're making a cost-effective design to mass produce? Because that is our end goal. Our goal is to

Paul Davis: ensure our clients are making cost-effective and quality designs for them to move into mass production.

Paul Davis: And it all starts from that original CAD design, where we're always considering

Paul Davis: in these form factors and manufacturing constraints moving forward into more refined CAD.

Kevin Mako: Yeah, that's so important, especially to do from the early design phases, because if you can think

Kevin Mako: of all these elements and understand how they all fit together, then it makes it exponentially easier as you

Kevin Mako: jump into prototyping to isolate certain things that you can't tell. What are some of the unique facets

Kevin Mako: of this product that we really have to test in order to ensure and just focus on improving those things?

Kevin Mako: The other things we know, we've already designed it for manufacturing, we've got good quality parts

Kevin Mako: and all of the elements of draft angles and part tolerances.

Kevin Mako: and materials specification documents, et cetera, are solid.

Kevin Mako: But if we drill down into the parts that we're really not sure of, maybe something connects,

Kevin Mako: is there a weak point?

Kevin Mako: What are the stress points?

Kevin Mako: It allows us to hyper-isolate on those things as we move into prototyping phases so that we're

Kevin Mako: not testing a whole variety of random things and we're isolating on really just the breakpoints

Kevin Mako: or the unknowns.

Kevin Mako: And that's how you can create a great product because every product is unique.

Kevin Mako: Even if it's a relatively simple product, there's going to be a handful of custom things on that

Kevin Mako: product that is unique to you that will have its own challenges that need to be solved.

Kevin Mako: It's always the case with really any hardware product.

Kevin Mako: So as you get into the prototyping phase, if you've really built out a strong CAD model with

Kevin Mako: a lot of the redundancies built in from day one, then it allows you really to build the best

Kevin Mako: possible product also considering cost.

Kevin Mako: So you're both focusing on quality and cost at the same time.

Kevin Mako: So fundamentally, building the platform strong is extremely helpful.

Paul Davis: I always see the clients early on and something scares them off, but

Paul Davis: nine times out of ten that doesn't is you don't want to go into your product development

Paul Davis: journey and jump straight to production.

Paul Davis: I know this touches more on the prototyping side, but you don't want to drop, say, 50K on

Paul Davis: tooling for a hinge not to work, for example.

Paul Davis: It's very hard to change tooling once you've committed to it.

Paul Davis: So prototype, prototype, prototype until you get to the stage where you're really confident

Paul Davis: and then that's where we start to dissect the CAD, get it manufactured already.

Paul Davis: We talk to engineers, these tooling experts don't what they're talking about,

Paul Davis: and we can get a really nice production of ongoing.

Paul Davis: I also like to mention that even when you do get to the stage where you're made tooling for your part,

Paul Davis: they're not just going to pump out your first 1,000 units.

Paul Davis: You will get to see a production sample to make any final adjustments that you want to make.

Paul Davis: Do one final checkover and make sure you're happy.

Paul Davis: Because that's that question I get asked a lot.

Paul Davis: It's like, that's it.

Paul Davis: We're going to just make a thousand units and we're selling them now.

Paul Davis: It's like, no, no, you have time.

Paul Davis: You have time to have a look.

Paul Davis: Ideally, you don't have to make any changes at that point because it can be,

Paul Davis: there's a lot more complex to make tooling changes.

Paul Davis: But it's always nice to know that you will have that final unit in your hand before you

Paul Davis: pull the trigger.

Kevin Mako: Yeah, I mean, that's always a super helpful pace.

Kevin Mako: It's usually an exciting thing.

Kevin Mako: And this whole thing comes around the theme is if you invest a little bit more up front

Kevin Mako: for every phase following, it makes those phases easier, faster, smoother.

Kevin Mako: If you look at the life cycle of a product from Sketch all the way through to

Kevin Mako: scaling up production.

Kevin Mako: Those who really designed and built and thought the product through early

Kevin Mako: are going to spend exponentially less than those that thought they were saving money by cutting

Kevin Mako: corners.

Kevin Mako: Those corners that you cut become way more expensive down the road.

Kevin Mako: And although a lot of people like to pass the buck forward when they think it, you know,

Kevin Mako: makes sense to save a couple bucks today, just know that at some point that day is going to

Kevin Mako: arrive.

Kevin Mako: And it's going to be a very problematic and difficult day.

Kevin Mako: There's already enough challenges in developing a new product.

Kevin Mako: So if you do it well, then you can seriously eliminate the vast majority of those challenges,

Kevin Mako: again, so that you can isolate on the very few unique, specialized challenges to really

Kevin Mako: create amazing IP in a great product.

Kevin Mako: That's what makes for an amazing product.

Kevin Mako: You've thought both about the user, but also the manufacturability, the quality standpoint,

Kevin Mako: and simplicity of the product, especially as a hardware startup.

Kevin Mako: One of the things that we typically drill down on in the actual actual.

Kevin Mako: industrial design phase is what we call concept mechanical.

Kevin Mako: And this is where you're not just doing typical visual design, but the mechanical engineering

Kevin Mako: that actually builds the foundation of the product as well underneath.

Kevin Mako: And that's a lot of the concepts we're talking about are looped into this overarching

Kevin Mako: concept of concept mechanical engineering, essentially building out as much of the

Kevin Mako: internal mechanics and ribbing, et cetera, that builds, let's call it the internal

Kevin Mako: skeleton of the project, so that the external works well.

Kevin Mako: The features, functions, et cetera.

Kevin Mako: Now, it's not exactly as clear cut as that.

Kevin Mako: Sometimes the external is the internal is the internal, but the point being is that you've got to focus

Kevin Mako: both on function, aesthetics, sexiness, modernness, as well as detailed engineering,

Kevin Mako: engineering, engineering, planning, part procurement, et cetera, so that you have both

Kevin Mako: in order to really manufacture great product.

Paul Davis: You're finding that balance.

Paul Davis: You want to spend the function.

Paul Davis: You want it to be quality.

Paul Davis: You want to be cost effective.

Paul Davis: But you also want it to be eye pop.

Paul Davis: You want people that want to buy this.

Paul Davis: Once you strike.

Paul Davis: that perfect balance between aesthetics, function, quality, cost effective.

Paul Davis: You can really, really build on that first product.

Paul Davis: And that's when it gets exciting.

Paul Davis: That's definitely the perks of this job is getting it to that stage.

Paul Davis: The seeing client success stories.

Paul Davis: It's heartwarming.

Kevin Mako: That's one of the most beautiful parts of the job.

Kevin Mako: It's that transition from, you put all this work into all that development, design, engineering,

Kevin Mako: prototyping, getting everything prepared for manufacturing, getting manufacturing set up,

Kevin Mako: doing the production sample, making sure that.

Kevin Mako: that production sample is perfect based on everything that's been done up to that point

Kevin Mako: in time, and then actually seeing your units start to hit the shell.

Kevin Mako: So that really is a special moment.

Kevin Mako: I like how you put it, heartwarming.

Kevin Mako: That's the perfect way to describe it because it's really a magical moment where you go from

Kevin Mako: investing into the business to now starting to flip the switch.

Kevin Mako: It'd be like, okay, let's start scaling up sales.

Kevin Mako: Let's start monetizing this, start making money and bringing it in.

Kevin Mako: And then expanding the brand.

Kevin Mako: And I think what's so amazing, especially for first-time founders,

Kevin Mako: Once you understand the process of how to design develop a product well from the beginning,

Kevin Mako: you see it go through, you see it come to life, all of a sudden, it enhances your ability of a founder

Kevin Mako: to execute on those ideas, not just on the first product that you developed, but from there,

Kevin Mako: you almost always inevitably start coming up with the pro version or the accessories for this

Kevin Mako: or different markets for the product.

Kevin Mako: And then that is how really brands start.

Kevin Mako: If you look at all the world's major hardware brands, they started somewhere.

Kevin Mako: They almost always started one relatively simple product that solved a very important pain point

Kevin Mako: for a handful of people.

Kevin Mako: And then from there, they scaled.

Kevin Mako: And that's the best way that you can look at a hardware startup especially is start small.

Kevin Mako: We talk about MVP, strip down the features, spend less with your industrial design firm on less

Kevin Mako: features, but of the features that you do, make sure you nail those out of the part.

Kevin Mako: High quality, cost effective, built to global standards.

Kevin Mako: all of the rest that we talk about.

Kevin Mako: And if you do it that way, you have an amazing product that hits the market.

Kevin Mako: You start to scale that and then you start developing your next iterations or inventions.

Kevin Mako: Or if the product continues to sell and you just want to focus on sales, sales,

Kevin Mako: sales, and profitability, then you ride that wave, sometimes for years.

Kevin Mako: People will ride one product for decades.

Kevin Mako: So it's totally up to you as the founder.

Kevin Mako: And obviously, the hard work's going into that.

Kevin Mako: But I think the biggest point of this podcast is start early on that process,

Kevin Mako: start early doing things the right way.

Kevin Mako: And that smooths everything out for you going down the channel and getting that business off the ground.

Paul Davis: Yeah, honestly, like, it really is the reason I love working at Mako.

Paul Davis: A lot of success stories.

Paul Davis: And being able to actually purchase something from a store that you made is always really rewarding.

Paul Davis: So I look forward to many more projects.

Paul Davis: And like you mentioned, like, come up a nice, simple idea.

Paul Davis: It may be sound too simple at the start, but you'll get there.

Paul Davis: Although we have a wide range of diverse products, I've brought textile products to market,

Paul Davis: mechanical handheld tools.

Paul Davis: They all have one thing in common, and it's the disk keep it nice and simple, few parts and very easy

Paul Davis: to manufacture.

Paul Davis: I think if you take those three boxes, you are setting yourself up for success.

Paul Davis: It's really rewarding to get to that stage.

Kevin Mako: Well, Paul, thanks so much for all your words of wisdom.

Paul Davis: Thanks for having me, Ken.

Paul Davis: Absolutely pleasure.

Kevin Mako: Thanks, Paul.

Kevin Mako: I appreciate being on the show.

Kevin Mako: We'll talk again soon.

Kevin Mako: Cheers.

Kevin Mako: Thanks for tuning in to this episode of the Product Startup Podcast.

Kevin Mako: If you found some value in the show, please do us a huge favor and hit the light.

Kevin Mako: button and subscribe. If you have any questions, guest suggestions, or anything else,

Kevin Mako: feel free to reach out to us anytime at our email, podcast at MakoDesign.com. This show is hosted

Kevin Mako: by Kevin Mako, North America's leading expert on product development for hardware startups.

Kevin Mako: And the podcast is produced by Mako Design, the original firm providing end-to-end consumer

Kevin Mako: product development services tailored specifically to hardware startups, small manufacturers,

Kevin Mako: and inventors. Take your product from idea to store.

Kevin Mako: shelves at MakoDesign.com. That's M-A-K-O-Design.com. Thanks for joining and see you again soon.

Manufacturing Readiness Strategy for Founders

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