Development Process

Optima’s 5 stages to successful product development

At Optima Design, we utilise a five-stage development process to ensure high-quality products are developed, with a clear and transparent workflow for our customers. Each stage is tailored to meet specific customer requirements, and we offer support at any stage of the cycle—from research to final product delivery and ongoing support. Whether clients need assistance with a single phase or full-cycle product development, we are equipped to handle it. The diagram below illustrates a typical full-cycle development process, highlighting how we guide clients through each step to deliver innovative, functional, and manufacturable products.

IP Roundal

Discover

At Optima, creating outstanding products and delivering compelling user experiences begins with a thorough understanding of user behavior. By analysing users in the context of their environment and exploring applicable technologies, we can craft user-centric solutions that genuinely meet their needs.

In addition to understanding the user, we also conduct in-depth market research, including competitive analysis, to identify emerging trends within specific product and service sectors. This ensures that our proposals are not only user-driven but also aligned with broader market opportunities.

Our comprehensive discovery phase provides us with a solid foundation of information, allowing us to confidently proceed to the development stage with well-informed decisions.

 

Concept

After the discovery phase, the next step is to generate concepts through sketches, mock-ups, exploratory images, and rendered CAD models based on the design brief. These initial concepts define the product’s aesthetic and functional requirements, guiding further development.

Key factors like user interaction, aesthetics, ergonomics, and manufacturing feasibility are integrated from the outset. Early involvement of suppliers is common, as their expertise in materials and production methods ensures the design is practical and manufacturable.

Preliminary cost estimates are gathered to give clients a clearer understanding of the project’s financial scope. These estimates help clients make informed decisions about technologies and manufacturing techniques, aligning the design with their budget and goals.

Additionally, concept-level renderings and images are produced to visualize the design. Clients use these visuals to evaluate market potential, secure stakeholder support, and conduct early promotional activities, helping to gather feedback and build momentum as the project progresses.

Engineer

Once the concept phase is complete, the chosen design is refined using advanced CAD software to create a fully defined 3D model. This ensures the product’s form, fit, and function are optimised, allowing it to perform as expected and preventing costly issues later in development.

Tools like Finite Element Analysis (FEA) and Design for Manufacture and Assembly (DFMA) are used to enhance the design. FEA evaluates material behaviour, stress points, and structural integrity, while DFMA ensures the design is cost-effective and easy to manufacture, reducing production complexities.

Rapid prototyping is crucial at this stage, enabling the creation of physical models for evaluating ergonomics, fit, and aesthetics. This hands-on approach helps identify issues early, before they become expensive problems.

Prototypes also allow clients and stakeholders to provide direct feedback, which is often more insightful than renderings alone. This collaborative process ensures the final design meets expectations and reduces costly revisions later on.

Optimise

Complex designs often require multiple iterations to achieve the desired result. Feedback from stakeholders and ongoing testing drive necessary changes, ensuring that the design evolves into the most effective version. This iterative approach allows for continuous refinement based on real-world insights.

During the optimisation phase, detailed costings are developed using quotes from various supply chain and manufacturing partners. This step is crucial for aligning the design with the project’s budget and timeline. Accurate cost estimates for materials and manufacturing processes allow for informed decision-making about the best approach to production, avoiding unexpected expenses.

With these costings in place, manufacturing planning becomes more efficient, ensuring that potential challenges are anticipated and addressed. This careful financial planning helps ensure that the project stays on track, both in terms of budget and timeline. By combining design iteration with strategic cost management, the project can move forward smoothly, resulting in a successful final product.

Deliver

Product delivery is a comprehensive process that goes beyond the final product. We can provide photo-realistic visuals that showcase the product from every angle, helping clients visualise the design for presentations, marketing, and promotional purposes.

We also offer detailed assembly instructions, ensuring that the product can be assembled easily and safely. Our instructions are clear, with step-by-step guidance and easy-to-follow diagrams.

In terms of branding and packaging, we collaborate with clients to create customized solutions that reflect their brand identity. We design visually appealing and protective packaging that enhances the customer experience while ensuring the product’s safety.

Additionally, we develop animations for marketing to highlight the product’s features and functionality in an engaging way. These animations are perfect for use in promotional videos, social media, and websites, helping to capture customer interest and drive product awareness.

Together, these services ensure a complete, market-ready product.

We pride ourselves in our pragmatic and collaborative approach, ensuring clear communication to clients using virtual and onsite meetings and regular progress updates and Gateway reviews. Over 25 years we have found that direct client involvement in critical decisions is the most successful way of ensuring that all expectations are met and that the final product is one everybody can be proud of.

Please contact us to discuss your product development requirements, we are always happy to formulate a flexible package of work applicable to your project needs.

Frequently Asked Questions

Turning your idea into a product is exciting, but can feel daunting. With so much to think about—like market demand and technical challenges—it’s easy to question whether your product is worth pursuing. Below are a range of commonly asked questions which can help guide your decisions, evaluate the viability of your product and to help make decisions about the best route forward. We always advise engaging with us in the early stages of consideration, so we can support your decisions with our expertise.

Is my product idea worth developing?

arrow_drop_down

There are many factors which can effect the viability of your new product idea. These include; real-world market opportunity, existing products, technical feasibility, risk v’s reward, timescale of development, existence of suitable technologies and availability of funds. We have in-depth experience of gauging the feasibility of new product ideas and can guide the process from assessment of market, technological feasibility, costing and routes to final delivery. Our central focus is to undertake projects which are viable and lead to real world solutions being launched to market.

Will I be involved in the design process?

arrow_drop_down

Yes, we employ a highly transparent, collaborative approach and encourage you to be fully involved in the Design and Development process. Often you hold the key information and learning, which we need to fully understand to develop the best products. We keep our clients regularly updated with progress, challenges and costs by screen-sharing and in-person meetings. We want our clients to feel fully included and happy with the results of any development process.

Do I need to have previous product development experience?

arrow_drop_down

No, we deal with both new start up’s and established manufacturing businesses. We can provide full-service design and development and complimentary assistance where required. Previous product development experience is not a prerequisite to engage with us in the development of your product ideas.

Do I need to have existing drawings of my design ideas?

arrow_drop_down

No, we can work from verbal or written descriptions, or more detailed drawings of a design concept. We always propose a kick-off telephone call, screen share or in person meeting so we can gather as much information as possible about a product proposal, background to the idea, and long term goals. We also offer full ground-up development services and can formulate inventive concept solutions to an existing design problem, which has been identified.

Will my new product ideas and inventions be safe?

arrow_drop_down

Yes, we follow a standard practice of issuing legally binding Non-Disclosure Agreements (NDA’s) to protect both parties and their intellectual property. This ensures that technical and proprietary information can be shared securely. Additionally, we only collaborate with trusted partners, all of whom are covered by comprehensive NDA’s. We are also happy to review and sign existing NDA’s, should they be required by established companies.

What funding is available for New Product Development?

arrow_drop_down

There are several sources of research and development (R&D) funding, depending on industry, location, and project stage. Government grants and incentives, such as innovation grants (Innovate UK, Horizon Europe) and R&D tax credits, help reduce costs and encourage innovation.

National science and research councils also provide funding for academic and industrial projects. Private investment options include venture capital, angel investors, and corporate partnerships, which can offer both funding and strategic support. Universities and research institutions often provide grants for joint industry research, while incubators and accelerators offer funding, mentorship, and networking opportunities.

Alternative financing methods, such as crowdfunding through platforms like Kickstarter or Indiegogo, can help early-stage projects gain traction.

We can offer support and assistance in sourcing Research and Development funding to help develop your product.

How long does the development process take?

arrow_drop_down

Project timelines depend on the technical complexity of the product. Simple designs may take weeks, while complex electro-mechanical systems can require months or even years. We assess technical feasibility, estimate costs and timelines, and identify risks early. Generally, the more unique or intricate a product, the longer it takes to design, prototype, validate, and transition to manufacturing. Solving complex electro-mechanical challenges is an iterative process, often requiring multiple prototypes to ensure reliability in real-world conditions.

Other factors affecting timelines include; market certifications, component availability, manufacturing schedules, and ongoing funding availability.

What resources are required?

arrow_drop_down

This is highly project specific and dependent on the type of client we are dealing with, from first time start-up to established businesses. We can provide part, or full-service development, specifically tailored to individual requirements. Common resources required to develop a product include; concept and CAD design, detailed engineering, electronic and PCB development, IP evaluation and consultation, mechanical prototyping and manufacturing specification and liaison. We can advise on resource requirement including offering technical expertise and resource planning, help build the right team of suppliers and offer advice on funding and product delivery.

Do my product idea’s require prototyping?

arrow_drop_down

Almost, always, yes. Prototyping takes many forms, from a simple paper sketch or foam models, to a fully functioning electromechanical design. It is one of the most valuable tools for evaluating and refining a concept. We recommend various prototyping techniques throughout the development process and collaborate with specialist prototype supplier in the UK and the Far East to achieve the best blend of accuracy, cost, and timescale.

Who own’s the intellectual property (IP) contained in my product?

arrow_drop_down

You do. We can help develop solutions which incorporate unique features, applicable to intellectual property registration. You, as the paying client, own the intellectual property of any feature or mechanism which we develop. Where ‘inventor citation’ is required for the Patent Office, we sign an IP transfer document which means that you own, outright, any IP which is integrated into your product. This allows you to exploit, maintain or transfer any IP without recourse to consultation with us. This includes Patents, Design Registrations, Trade Secrets and Trademarks.

The ownership of patents not only gives market Kudos, and confidence to potential investors, but can also open opportunity for governnment backed schemes like The Patent Box. This scheme can provide tax breaks for companies investing in R&D. We can advise on whether your products are applicbale to this scheme, and also help develop unique IP which can open routes to additional financial benefits.

How can I get my products manufactured?

arrow_drop_down

We have strong partnerships with prototyping and manufacturing specialists who handle both development prototyping and final production. We can manage the entire manufacturing process for you or provide supplier contacts for self-management. For established companies, we are also happy to collaborate with existing suppliers or in-house manufacturing teams.

What are the risks in new product development?

arrow_drop_down

Risks in new product development (NPD) often stem from complexity—the more intricate a product, the greater the risk. Below are key risks that must be actively managed:

Funding Availability – Successful product launches go beyond development. Costs extend to tooling, manufacturing, certifications, marketing, packaging, distribution, and ongoing support. We offer full-service product development, including cost assessments and funding guidance, from innovation grants to tax incentives.

Technology Availability & Development – Most products require problem-solving to ensure functionality and manufacturability. The more complex or unique a product, the higher the risk, especially when integrating intricate components and mechanisms. The most effective approach is often the simplest solution which fulfils the products functional requirement cost effectively.

Insufficient Development & Manufacturing Timelines – Realistic timelines are essential for robust design, evaluation, and testing before transitioning to manufacturing. Production timelines must also account for tooling, assembly, certification, and distribution.

By addressing these risks early, we help ensure a smoother and more successful NPD process.

Emergence of competitive products, or changes to market conditions – In competitive markets, there is always a risk that new solutions may emerge to address similar problems. Timing is often critical to success. Our approach involves assessing market conditions and existing intellectual property while advising on IP protection strategies. This ensures that the product being developed is both valid and capable of solving real-world problems effectively. We partner with specialist IP advisors who can provide services ranging from IP searches, to full patent, design protection and trademark registration.

How can I promote and market my product?

arrow_drop_down

We are not specialists in the promotion or marketing of products. We can however offer support with packaging, instructions, photo-quality renders, animations and other related marketing materials to assist in funding pitches and promotional material development. We can also source high-quality presentation models which can be useful for marketing photography, stakeholder buy-in, trade show demonstrations and crowdfunding campaigns.

Research & Innovation

More arrow_forward

Industrial Design

More arrow_forward

Engineering Design

More arrow_forward