A Guide to the Product Design Process: From Brief to Build
Bringing a product from initial brief to market launch is a demanding process. It requires far more than great ideas: it demands strategy, collaboration, and a deep understanding of technical, commercial, and human factors.
At Industrial Design Consultancy (IDC), we have developed a strategic and robust process that guides clients through every phase of development, ensuring that great ideas become exceptional products.
Whether it’s a medical device, industrial equipment, transport innovation or a consumer product, our team unites design, engineering, and prototyping expertise under one roof. This integrated approach is key to solving complex challenges and accelerating time to market.
Below, we break down the four key stages of IDC’s product development journey, from insight to implementation.
Explore: Defining the Opportunity
The first step in any successful design process is gaining a full understanding of the problem and the people it affects. During the Explore phase, we conduct in-depth user research, market analysis, competitor benchmarking and stakeholder interviews to define the opportunity space and align on project goals.
Rather than making assumptions, we take time to uncover real user behaviours and technical constraints. This research lays the strategic foundation for the project and ensures that every decision that follows is grounded in insight. We capture requirements across disciplines (clinical, mechanical, electronic, regulatory) and create clear briefs that guide the creative and engineering process.
Create: Ideating, Sketching, and Conceptualising
In the Creation stage, our team takes ideas generated and transforms them into tangible concepts. This phase is where creativity and innovation take centre stage. We explore multiple directions through sketching, CAD modelling, and rapid prototyping to visualise solutions and stress-test their feasibility early on. We consider not only form and aesthetics, but also ergonomics, usability, brand language, and market positioning. Concepts are iterated rapidly, incorporating client feedback, technical reviews and user testing to ensure we are solving the right problems, in the right ways. By the end of this stage, we’ve shaped a compelling design direction that can be confidently taken forward.
Define: Engineering the Detail
With a validated design in place, the Define phase is focused on refinement. Our mechanical and electronic engineers collaborate with the design team to ensure that the product is technically sound and production-ready. We build comprehensive CAD assemblies, evaluate material choices, run simulations (such as FEA and thermal modelling), and work with regulatory consultants to address relevant standards and certifications.
We also begin preparing for manufacture: designing for injection moulding, assembly, and testing, and specifying finishes and tolerances. Prototype testing continues during this stage to validate functionality, robustness, and performance. Every detail is addressed to ensure a seamless transition into tooling and production.
Deliver: From Tooling to Production
The final phase is about bringing the product to life at scale. Our production support team works with clients and suppliers to manage the transition from prototype to volume manufacture. This includes supplier sourcing, tooling design reviews, mouldflow analysis, and detailed inspection of first-off parts.
We liaise directly with toolmakers and moulders to review samples, approve tooling, and establish robust quality checks. Our hands-on support ensures that manufacturing risks are reduced, production timelines are optimised, and quality remains high. We also assist in RFQs, supplier evaluation, and integration into existing supply chains, adapting our level of involvement to suit the client’s needs.
Case Studies: From Brief to Build
Axiom Injection Pen – Shaily Plastics
Shaily Plastics partnered with IDC to create the Axiom Injection Pen: a fixed-dose medical device designed for a range of treatments, including HGH and GLP-1 therapies. The goal was to deliver a versatile, cost-effective solution for pharmaceutical clients.
We developed a unique pull-to-dose mechanism to ensure safety and dosing accuracy, while avoiding existing patent conflicts. Prototypes were rapidly produced in-house for testing, allowing swift iteration.
The final design met ISO 11608 and FDA requirements and was optimised for volume manufacture using medical-grade plastics. Axiom is now commercially available and used globally.
TranQuill Tattoo Device - Active Needle
Active Needle partnered with IDC to develop the TranQuill Tattoo Device: an ultrasonic tattooing tool designed to dramatically reduce patient pain while meeting the ergonomic needs of professional artists. Originally created for medical injections and biopsies, Active Needle’s technology faced challenges when adapted for tattooing, including excessive vibration, weight, and wiring failures.
IDC engineered a solution using counterbalancing mechanisms, dual-output motors, and custom-built components to minimise vibration and improve reliability. Extensive user interviews informed the design of a refined handpiece and console tailored to tattoo studios.
The result was an advanced prototype which reduced average pain scores by more than half in testing and enabled Active Needle to licence the technology to a leading tattoo brand.
At IDC, our process is not only proven, it’s agile for unique client and market needs. We understand that each project is different, which is why our clients can engage with us at any stage of development, from early insight to full production management. Our UK and China teams collaborate closely, offering global delivery with local understanding. And with ISO 9001 and ISO 13485 certification, we bring robust quality management to every product we help create. Explore our full design process to see how each step can be tailored to your needs. Have a new idea or need to improve an existing product? Whether it’s a handheld device, complex user interface, or large-scale industrial tool, IDC’s integrated team is ready to help. With over 50 years of experience and a proven track record of market success, we’re your partner from first brief to final build. Get in touch with us today and begin your product journey.Strategic Process for Global Success
Ready to Bring Your Product to Life?
