Prototype To Manufacturing Services

Are you wondering how to move your idea from a prototype to a manufactured product? At Idea Reality we have over a decade of experience helping inventors get their products to market.

Speak to our design team

Once your prototype is performing as expected, and the design is finalised, you will be in the perfect place to quick off one of the most exciting stages of the product design journey – manufacturing your final product! And our team will support you through it.

Supporting you all the way

Project review & proposal

Submit your project info and get honest feedback from our award-winning design team. If we can help and add value, we create a detailed, tailored project proposal for you outlining costs and options

Speak to our design team

Design & prototype

Embark on an exciting product development journey with us. Taking your ideas from innovative conceptual designs through to engineered 3D CAD models and working elecro-mechanical prototypes!

Speak to our design team

Manufacture, launch & market

Turn your product idea into commercial reality! We support you with the patent process, setting up your manufacturing partnerships and even creating websites, video content and brand identity.

Speak to our design team
face reformer neckline trainer prototype to manufacturing

Prototyping VS Manufacturing

The way in which your product is prototyped typically differ to manufacturing processes, for example, the 3D printing process is very different to injection moulding at scale. This means your design will need to be adjusted according to each stage of the process. Our award-winning team will have Design for Manufacturing in mind from the start of the design process and will ensure any 3D files are adapted for prototyping along the way, to suit your project’s needs and stage of development.

Design for Manufacturing

Design for Manufacturing is an essential part of the Product Design Process. To keep mass production costs low, we must carefully consider the end production process, manufacturing requirements and best design practices at the earliest possible stage to ensure your product can be produced efficiently. Moreover, as we progress the design from a prototype to production, tweaks must be made to ensure parts are suitably redesigned for mass manufacturing.

Drageekiss cake pearl applicator product design manufacture

  • 3D Printing to Injection Moulding

    Geometry constraints vary greatly between these two processes. Although injection moulding requirements will be considered from the early design stages, CAD files might need to be tweaks for effective prototyping.

  • Laser Cutting

    Unlike injection moulding, some mass manufacturing techniques, such as laser cutting, are suitable for both prototyping and mass manufacturing. This means the transition from prototyping to production will be more straight forward.

  • Sheet Metal

    This process is also applicable for both prototyping and mass production, therefore design requirements will remain the same. Costs will likely go down as order quantities increase, compared to one off units.

Hear it from our customers

Idea Reality’s expert design team uses the latest software to develop, simulate and engineer the 3D models of your product design idea

Formlabs 3D printer Idea Reality Office

Prototype Review and Testing

One of the most important reasons why a design should be prototyped is to ensure it performs as expected, and ensure it meets the target users’ needs. Prototypes are developed throughout the design journey and will help inform any needed tweaks. This iterative prototyping process allows us to nail down the ideal use scenario and user experience as effectively as possible. Doing this before investing in any tooling can save you from spending unnecessary money in tooling for a product that doesn’t perform as desired.

CAD Updating

Once the design is finalised, our experienced design team will thoroughly review the 3D CAD files for your project and apply any updates to make sure the product is suitable for the selected manufacturing process. For example, when injection moulding is used for manufacturing, it is essential to avoid any undercuts, include the appropriate tolerances and ensure draft angles are applied to facilitate part removal from the mould tool.

cad design
Measuring and precision concept

Manufacturer’s Feedback

Once the CAD files are ready, we will send them to several of our trusted suppliers for feedback and quoting purposes, along with a thorough Manufacturing Specification Document. Factories will usually review the files internally with their engineering team, and if needed, request any last tweaks to the parts so they are better suited for their particular machines and processes.

Why work with us?

Free idea review

We will review your idea for free and let you know from the start if we are the best product design team to help!

Tailored Process

Every stage of the product design process is tailored to your unique project needs, giving you efficiency and the best value.

Personal Service

Get direct contact and support from our design team and always have full control of the project pace and direction.

Confidentiality Assured

You retain 100% of your idea and any new IP we develop for you. All communication and project details are kept confidential under a Non-Disclosure Agreement (NDA).

Broad Expertise

We work across a variety of sectors and types of products, giving us a broad experience in multiple manufacturing processes and a vast network of suppliers.

Funding Support

We can support you by creating all the necessary marketing materials to take your idea to customers, investors or even create crowdfunding campaigns.