This is the methodology that MAS Design has used successfully on a variety of new product developments. In this particular case, the methodology is for a typical mechanical/structural product. It is assumed that the product specification is clearly known and that all the market and user research has been completed. Some of these steps may be iterative. (The images on the left give examples of various stages in the process for different projects).
> Brainstorming (alone and with colleagues) to generate a large range of concepts including radical as well as obvious solutions.
> Sketch-drawing and sketch-modelling in order to explore the ideas generated above.
> Checklists and scoring techniques are used to shortlist the best concept ideas.
> Shortlisted concepts are drawn to scale, initially by hand in 2 dimensions, then on a CAD (computer aided design) system in 3 dimensions. N.B. CAD systems allow concepts to be refined and mechanisms to be simulated quickly and at a low cost. This means a larger number of alternative solutions can be explored than with physical modelling. Therefore the chance of finding the optimum solution is greatly increased.
> Functional, full-sized models are made based on the CAD solutions above. These test how the mechanisms work and feel. The processes of modelling a full-sized mechanism or product, in say wood, shows up aspects that are not always apparent on the CAD system.
> Using the same methodology the detailed design is refined following the establishment of the overall concept. As a result, a workable detailed concept is generated.
> Components and proposed materials are explored for size, strength/stiffness etc. Both manual stress analysis and CAD-based stress analysis can be used.
> Materials and process suppliers are investigated to ascertain availability and costing information. Expertise at Cambridge University and Imperial College may be used at this stage.
> Test rigs are built after optimisation of the mechanical concept. These will be able to take real loads, they verify the above work and allow for final refinement and optimisation. They will be incorporated into usable products to assess the performance accurately in real situations.
> Once verified for basic strength and function, rigs are also tested with a variety of potential users; feedback at this stage is vital. Test houses are also used to check performance independently and to ensure compliance with various standards.
> Market and user research is carried out. Until the design is frozen, it is subject to intensive rounds of improvements. At this stage patents are usually finalised and applications made.
> Key suppliers are finalised and the design is detailed according to their processes.
> Where possible, CAD data used throughout the development process is also used for tooling and creating manufacturing drawings. These are made with working tolerances, material specifications etc.
> Involvement continues until beyond product launch, as much information has to be documented and passed on to manufacturers, assemblers and the business as a whole.
