Product Development

How We Work
We help clients take validated designs through engineering, prototyping, and manufacturing — turning approved concepts into production-ready products.

Our process integrates technical strategy with hands-on problem solving, ensuring every product is engineered for performance, cost, and scale from the start.
System & Product Architecture Definition
We define how a product comes together — the relationship between enclosure, electronics, mechanical systems, sensors, and user interface. Our architecture work establishes component layout, thermal management strategy, assembly sequence, and critical tolerances early, so engineering decisions downstream are informed by intent rather than improvisation.
Engineering & Implementation Partnership
We work alongside your internal engineering team or third-party partners as a design engineering extension — reviewing mechanical and electrical designs, resolving tolerance and assembly conflicts, and ensuring that industrial design intent carries through to production. We stay involved from EVT through DVT and PVT, not just handoff.
Invention, Innovation & IP Creation
Many of our projects produce patentable innovations in form, mechanism, interaction, or manufacturing method. We have contributed to over 300 patents across our portfolio. When a project demands a novel solution, we develop it, document it, and support the patent filing process with detailed drawings and functional descriptions.
Proof-of-Concepts
Before committing to full development, we build proof-of-concepts that validate critical unknowns — whether that's a new mechanism, a material behavior, a sensor integration, or a user interaction. Our POCs range from rough functional rigs to polished working prototypes, depending on what needs to be proven and to whom.
Creative Engineering Leadership
Some projects need more than engineering support — they need someone to define the technical direction. We provide creative engineering leadership for teams that have design vision but need a partner to determine how to build it, what's feasible within timeline and budget, and where to push the boundaries of what's possible.
Technology Integration
We help clients incorporate emerging and complex technologies — sensors, wireless connectivity, embedded computing, motors, actuators, optics, and battery systems — into products that feel simple to the user. Our role is to bridge the gap between raw technology capability and a refined, manufacturable product experience.
Design for Manufacture & Assembly (DFMA)
We optimize designs for efficient, cost-effective production. Our DFMA work includes part consolidation, draft and wall thickness analysis, snap-fit and fastener strategy, tolerance stack-up review, and material selection aligned with production volume and method — whether injection molding, die casting, sheet metal, or overmolding.
Manufacturing Strategy
We help define how and where your product gets made. This includes recommending production methods, identifying appropriate manufacturing volumes and processes, planning tooling phasing, and structuring a path from pilot runs to scaled production. We draw on decades of relationships with domestic and international manufacturers.
Cost Optimization
We reduce product cost without reducing product quality. Our cost optimization work identifies opportunities in material substitution, part count reduction, assembly simplification, and tooling efficiency — always balanced against design intent, reliability, and user experience. We negotiate this tradeoff with precision, not compromise.
Partner Sourcing
We help clients find and vet the right manufacturing partners — from contract manufacturers and OEMs to specialty vendors for PCBs, injection molding, metal fabrication, finishing, and packaging production. Our sourcing recommendations are based on capability fit, quality track record, volume alignment, and geography, drawing on a network built over 25 years of shipping products worldwide.
We define how a product comes together — the relationship between enclosure, electronics, mechanical systems, sensors, and user interface. Our architecture work establishes component layout, thermal management strategy, assembly sequence, and critical tolerances early, so engineering decisions downstream are informed by intent rather than improvisation.
We work alongside your internal engineering team or third-party partners as a design engineering extension — reviewing mechanical and electrical designs, resolving tolerance and assembly conflicts, and ensuring that industrial design intent carries through to production. We stay involved from EVT through DVT and PVT, not just handoff.
Many of our projects produce patentable innovations in form, mechanism, interaction, or manufacturing method. We have contributed to over 300 patents across our portfolio. When a project demands a novel solution, we develop it, document it, and support the patent filing process with detailed drawings and functional descriptions.
Before committing to full development, we build proof-of-concepts that validate critical unknowns — whether that's a new mechanism, a material behavior, a sensor integration, or a user interaction. Our POCs range from rough functional rigs to polished working prototypes, depending on what needs to be proven and to whom.
Some projects need more than engineering support — they need someone to define the technical direction. We provide creative engineering leadership for teams that have design vision but need a partner to determine how to build it, what's feasible within timeline and budget, and where to push the boundaries of what's possible.
We help clients incorporate emerging and complex technologies — sensors, wireless connectivity, embedded computing, motors, actuators, optics, and battery systems — into products that feel simple to the user. Our role is to bridge the gap between raw technology capability and a refined, manufacturable product experience.
We optimize designs for efficient, cost-effective production. Our DFMA work includes part consolidation, draft and wall thickness analysis, snap-fit and fastener strategy, tolerance stack-up review, and material selection aligned with production volume and method — whether injection molding, die casting, sheet metal, or overmolding.
We help define how and where your product gets made. This includes recommending production methods, identifying appropriate manufacturing volumes and processes, planning tooling phasing, and structuring a path from pilot runs to scaled production. We draw on decades of relationships with domestic and international manufacturers.
We reduce product cost without reducing product quality. Our cost optimization work identifies opportunities in material substitution, part count reduction, assembly simplification, and tooling efficiency — always balanced against design intent, reliability, and user experience. We negotiate this tradeoff with precision, not compromise.
We help clients find and vet the right manufacturing partners — from contract manufacturers and OEMs to specialty vendors for PCBs, injection molding, metal fabrication, finishing, and packaging production. Our sourcing recommendations are based on capability fit, quality track record, volume alignment, and geography, drawing on a network built over 25 years of shipping products worldwide.

Throughout my career leading consumer electronics teams, I’ve consistently turned to Whipsaw for design support on complex challenges. They’ve repeatedly delivered innovative, award-winning solutions.

-
Chris Wheaton
Product Engineering Manager @ Meta

“Zero-to-one product development is a balancing act between vision and execution. With the right team and process, you can turn that balance into momentum.”

- Mike Elam

FAQ

What is your typical product development process?

Our product development process encompasses everything from concept to production. We typically start with a strategy & definition phase to align on user needs, business goals, and product requirements. We then begin our concept generation phase, which explores a wide range of possible futures for the product and brand. During this process, we integrate aesthetics, engineering, and DFM into our conceptual thinking. This ensures the product concept is both beautiful and functionally achievable. Once a final concept is selected, we continue through subsequent phases of refinement and development where every detail is defined, working alongside engineering, marketing, and our client to ensure the product that meets end users exceeds expectations.

How do you balance aesthetics and functionality?

Good product development means there is a healthy balance of both design sensibility and adherence to function. This way of thinking is critical, even in the early days of conceptual exploration, ensuring the design intent remains relatively unchanged through the refinement and DFM process.

Can you integrate emerging technologies into product designs?

Our team specializes in seamlessly integrating complex technologies into modern products, ensuring that innovation enhances rather than complicates the product's usability and performance. We are known as a go-to team for the “First Of” product designs.

Do you help clients select manufacturing partners & suppliers?

Yes, we connect our clients with vetted vendors, suppliers, and contract manufacturers globally. Our established network ensures reliable production partnerships tailored to your quality, volume, and budget needs.

How does Whipsaw handle the transition from prototype to production?

We use comprehensive Design for Manufacturing and Assembly (DFMA) processes to smooth the handoff from prototyping to production. This helps reduce risks, lower costs, and accelerate your time-to-market.

How involved can we be in the product development process?

We encourage close collaboration at every stage, from initial design refinement to final manufacturing strategy. This ensures the end product reflects your vision, brand identity, and business objectives.