1. Introduction: From Prototypes to Production
In the last blog, we explored the role of iterative development and the efficient use of prototypes – in all shapes and sizes – to reduce risk and test assumptions. This post looks at what happens next, as you step out of your development cave and into the real world of production.
The word production can mean very different things depending on context. Here, I’m using it to describe any product launch where you commit to manufacturing a batch of units – whether that’s a small pilot run, a medium-scale build for early adopters, or a large-scale launch into full commercial distribution.
In this blog, we’ll cover:
- Preparing for manufacture
- Planning your first production run
- The bits that often get overlooked
Reaching the point of production is exciting. It’s the moment your product starts to feel real. But it can also be daunting – you’re facing big decisions, significant spend, and the ultimate test of your design.
The good news? If your development process has been structured and strategic, production shouldn’t feel like a leap into the unknown. As we covered previously, your job in product development is to identify risks and systematically reduce them through building and testing.
As development progresses, those risks should get smaller – and more specific:
- From: Will it work at all?
- To: Can it work reliably, under these conditions, at this price point?
By considering manufacturing and production constraints early – not just at the end – you’ll be able to move into production with clarity, confidence, and far fewer surprises.
2. Transitioning from Development to Production
The shift from development into production can feel like a leap – but ideally, it should feel more like a confident step forward.
Previously we discussed how to use prototypes strategically to test assumptions and reduce development risk. If you’ve followed that process, your major risks – especially around user desirability and technical feasibility – should already be well understood.
In an ideal world, you only commit to a production run once you’ve exhausted your ability to reduce those risks through prototypes and small-scale tests. But in reality, timelines are often shaped by other pressures – stakeholder expectations, grant deadlines, seasonal launch windows, or cash flow constraints.
So if perfection isn’t always possible, what’s the baseline?
Before entering production, you should at minimum feel confident that:
- Your product functions safely and consistently in real-world conditions, using production-representative materials
- Real users have tested it (as far as possible) in realistic use scenarios, and you’ve addressed any unexpected use-risks
- There’s clear evidence of demand – ideally with customers ready to buy
Getting to this point shouldn’t require a last-minute scramble. These elements need to be baked into your development roadmap from the outset. Here’s how:
Involve users early and often
Keep testing with real users as you refine your design. Early testing uncovers unforeseen use risks and challenges assumptions. Later-stage testing validates performance, usability, and satisfaction.
Understand your production process – and design for it
Production methods come with specific constraints. If your final product will be injection moulded in polypropylene or machined in stainless steel, that matters.
- Investigate your manufacturing options early
- Choose a development partner familiar with your chosen route
- Prototype using materials or methods that simulate final production where possible
This avoids nasty surprises late in the process – like discovering your design can’t actually be manufactured the way you intended.
Engage with manufacturers early
Many first-time founders wait too long to speak to manufacturing partners – assuming they need a finished design first. But involving manufacturers early can improve both your product and your process.
- Manufacturers can spot design-for-manufacture issues early
- They may suggest small tweaks that reduce cost or improve quality
- Building rapport early helps avoid miscommunication and delays later
Build evidence of demand throughout development
Don’t wait until your product exists to start selling. You can begin gathering proof of demand through:
- Pre-sales or early-access signups
- Waitlists and lead magnets
- Customer interviews and willingness-to-pay tests
- Partner or distributor interest
These signals don’t just support investment – they give you confidence that production won’t be a shot in the dark.
Why it matters
The goal here is simple: to arrive at production without feeling like you’re gambling.
If you’ve done the work to reduce risk, validated your design with users, and engaged your production partners early, then moving into a first production run should feel like a logical next step – not a terrifying leap.
So what happens next?
Let’s look at some of the key production decisions you’ll need to make – and the bits that often get overlooked.
3. Key Production Decisions: What to Expect When You Go to Manufacture
Once you’ve reduced development risks through prototyping, you’ll be faced with one of the biggest steps in your journey – committing to production. And with that comes a major decision:
Where should you manufacture?
If you’re UK-based, you’ll typically have two main routes: manufacturing locally, or working with overseas suppliers – most commonly in Southeast Asia. Each option comes with trade-offs.
🏭 UK-Based Manufacture
- Most common production processes (e.g. injection moulding, CNC machining) are well covered by UK suppliers.
- Unit costs are typically higher than in Asia, though the gap is narrowing.
- You’ll often need to coordinate multiple suppliers – one for plastics, another for PCBs, packaging, etc. One-stop-shop solutions are harder to find.
- Be cautious of ultra-fast production offers. They can be useful when speed is essential, but often come with limitations in material choice, finish quality, or oversight.
🌏 Asia-Based Manufacture
- Particularly in China, there’s a vast range of suppliers offering just about every conceivable manufacturing process.
- In my experience, the quality is high, and prices are generally lower than UK-based options.
- A major advantage is vertical integration – many suppliers offer end-to-end services including plastic parts, electronics, assembly, and packaging. This can reduce complexity and streamline your logistics.
✈️ Logistics and Lead Times
- Shipping is a major consideration. While part fabrication may be faster overseas, freight can add significant time.
- Air freight is quicker but expensive – often only viable for small batches.
- Sea freight is cost-effective for larger runs, but expect several weeks or more in transit.
- Always build in contingency time for international shipping – especially if launch dates are critical. Over the past few years several major shipping issues have occurred leading to significant delays for deliveries.
🤝 Supplier Relationships
Don’t underestimate the value of close communication with your manufacturing partner. If you’re producing locally, an in-person visit can help you build trust and spot issues early. If you’re working overseas, make sure you have a clear point of contact and establish expectations early – especially around timelines, tolerances, and responsibilities.
4. What the Production Process Actually Looks Like
Production isn’t just about placing an order and waiting for finished products to arrive. It’s a collaborative process with several key stages – and plenty of back-and-forth along the way.
🧪 Step 1: Design for Manufacture (DFM)
Once you’ve selected a supplier, the first step is typically a DFM review. This involves the manufacturer reviewing your design to identify any issues that could cause problems during production. They’ll often suggest minor tweaks to:
- Reduce production costs
- Improve repeatability
- Avoid tool wear or geometry challenges specific to their machinery
These changes might seem small, but they can have a big impact on part quality and process efficiency.
📐 Step 2: Supply Detailed Drawings
Along with your 3D CAD models, it’s strongly recommended to supply 2D technical drawings. These may feel old-school, but they’re essential for:
- Highlighting critical dimensions and tolerances
- Communicating material or finish requirements
- Providing a clear reference in case anything goes wrong
Think of them as your product’s recipe – a shared agreement that both sides can use to verify what’s been made. I would be highly cautious of engaging in a production run without 2D drawings included as part of the agreement.
🧰 Step 3: Sample and Trial Runs
Most production runs go through at least two sampling stages:
- Test Shots / First Off Tool
- These are initial parts created to dial in the manufacturing setup.
- You might not see them, but the manufacturer uses them to calibrate equipment and refine settings.
- T1 Samples (Trial Production Parts)
- These are sent to you for review and approval.
- At this point, parts should be close to final — though minor issues may remain.
- You’ll check for fit, finish, performance, and consistency. Minor changes can often be made, but major ones may require expensive tooling updates.
- Final Production Run
- Once everything’s approved, the full batch is produced.
Final Tip: Production Is More Than Just Parts
This section focuses on producing the physical product – but don’t forget, a successful production run involves much more than just manufacturing the parts.
In the next section, we’ll explore the often-overlooked pieces of getting production-ready – from packaging and labelling, to storage, certification, and customer support.
5. The Bits That Get Overlooked
Launching a product is rarely as simple as hitting “go” on the production line. It involves a web of suppliers, milestones, approvals, and supporting materials – and it’s easy to overlook key steps when your focus is on getting the product itself ready.
Every product is different, and we can’t cover everything in a single blog. But here are some of the commonly overlooked elements that deserve early attention if you want to avoid last-minute headaches.
🎨 1. Aesthetic Finishing
Once your product is functional and manufacturable, you’ll need to make some final decisions around colours, textures, logos, and finishes. These choices may seem superficial – but they can have a huge impact on how your product is perceived.
- Colour in particular is a minefield. Everyone has an opinion, and decisions are often made on personal taste rather than user context or brand alignment.
- Surface texture affects perceived quality and durability – a matte finish can feel more premium, for instance.
- Logos and markings need to be considered for visibility, compliance, and long-term durability.
These details are part of the design process, not afterthoughts. Poor decisions here can seriously undermine an otherwise great product. Work closely with your design team, and resist the temptation to make last-minute, subjective changes. Trust the process – and test visual mockups with users where possible.
📜 2. Regulations and Compliance
Nearly all physical products – even non-medical ones – require regulatory consideration.
For Medical or Health-Related Products:
- Regulatory planning should start at the very beginning of development.
- Expect formal usability trials, documentation, risk assessments, and clinical validation.
- Consult with a regulatory expert early. Retroactively “bolting on” compliance is not viable – and likely to delay or derail your launch.
For Consumer or Industrial Products:
- The requirements may be less intensive, but still important.
- At a minimum, you need to back up your product claims and ensure you’ve taken appropriate safety steps.
- Some requirements can be self-certified, but proper documentation and testing are still essential.
Checklist:
- Have you identified which regulatory standards apply to your product?
- Are you CE or UKCA marked where required?
- Have you conducted relevant testing (e.g. drop tests, electronic safety tests)?
- Do your product and packaging include the required labels and safety markings?
Ignoring these until the last minute is a recipe for delays – or worse, liability.
📦 3. Packaging, Labels, and Instructions for Use
Beyond the product itself, there are several other deliverables you’ll need to launch successfully:
Packaging
- Your packaging is the first thing users see – it sets the tone for how your product is perceived.
- It also plays a critical protective role during shipping and handling.
- Don’t leave this to the last minute. Packaging often requires prototyping and iteration just like the product itself.
- Engage a packaging designer or supplier early in the process, and allow time for testing and refinement.
Labelling and Documentation
- Many products require legally compliant labels, including safety markings, batch codes, or contact information.
- You’ll likely need to provide instructions for use (IFU), safety notes, or other supplementary materials.
- These are often regulatory requirements – but they’re also a key part of the user experience. Poorly written or designed instructions can confuse users or undermine trust.
Like everything else in this post, these materials need budget, time, and expertise. Plan ahead, work with the right people, and prototype these elements just like you would with the product.
Conclusion: Production Is a Beginning, Not an End
If you’ve made it this far – well done! It should be clear by now that launching a physical product is no small feat. It’s a complex process involving a web of suppliers, partners, and technical decisions – all working together to deliver a well-considered, user-ready product.
This post hasn’t aimed to be exhaustive, but I hope it’s provided a realistic guide to some of the key steps (and common pitfalls) as you prepare for production.
But here’s the final point I want to leave you with:
Your product launch is not the end of development – it’s the beginning of the next phase.
The real test starts when paying users get their hands on your product. That’s when you’ll learn how it performs in the real world, where it falls short, and what future improvements or new offerings might be needed.
So keep listening. Keep testing. Keep evolving.
Product development is a cycle, not a straight line.
Thanks so much for following along with this blog series. If you’ve found it helpful – or if it’s raised more questions than answers – I’d love to hear from you. Feel free to reach out to discuss any part of the process.
And if you’d like the complete From Research to Reality series as a downloadable PDF (including tools, templates, and key resources), watch this space – I’ll be sharing it very soon.