Our Product Development Process
An end-to-end, proven approach to industrial design, engineering, and manufacturing - built to reduce risk and get products to market the right way.
From Concept to Production
At ReflexGRP, our product development process is designed to take ideas from early definition through full-scale production with clarity, rigor, and efficiency.
By combining industrial design, mechanical engineering, prototyping, and manufacturing expertise under one roof, we help clients build products that are functional, manufacturable, and ready to scale.
Our Process
Phase 0 — Project Definition
Setting the foundation for a successful product program.
We begin by aligning on goals, scope, budget, and timelines to ensure a clear path forward before design work begins.
What we do
Client interviews and requirement definition
Budget, schedule, and milestone planning
Project approvals and resource scheduling
Deliverables
Defined project scope and timeline
Signed agreements and formal project documentation
Phase 1 — Exploration
Understanding the opportunity before defining solutions.
This phase focuses on research, insight, and thoughtful exploration of the product landscape.
What we do
Market and user research
Competitive and comparative analysis
Feature definition and concept trade-off evaluation
Deliverables
Concept sketches and CAD visuals
Design review sessions and directional alignment
Phase 2 — Concept Modeling
Making ideas tangible to validate direction early.
Physical models allow us to quickly evaluate form, function, and usability before committing to engineering.
What we do
Rapid mockups and appearance models
Functional exploration where appropriate
Concept refinement and selection
Deliverables
Physical concept models
A single, approved concept ready for engineering
Phase 3 — Engineering
Turning design intent into manufacturable solutions.
Detailed engineering ensures every component is ready for prototyping and production.
What we do
Full 3D CAD development of components and assemblies
Material selection and part specification
Internal and supplier-informed design reviews
Deliverables
Complete 3D CAD assemblies
Engineering-ready designs for prototyping
Phase 4 — Prototyping & Iteration
Testing, refining, and improving through real-world feedback.
Prototyping is an iterative process that drives performance, durability, and cost optimization.
What we do
Fabrication of complete functional prototypes
Mechanical, functional, and visual testing
Iterative refinement based on testing and feedback
Deliverables
Fully assembled working prototypes
Optimized designs prepared for documentation
Phase 5 — Pre-Production
Defining every detail needed for repeatable, controlled manufacturing.
This phase finalizes every specification required to move confidently into supplier release and production tooling.
What we do
Finalization of manufacturing and assembly details
Definition of tolerances, finishes, and quality standards
Complete Design for Manufacturability (DFM) requirements
Deliverables
Complete manufacturing documentation package
Controlled files ready for supplier release
Approved design freeze for sourcing and tooling
Phase 6 — Sourcing & Costing
Aligning suppliers, cost targets, and production strategy.
We work closely with suppliers to refine cost, quality, and production readiness.
What we do
Release documentation to pre-qualified suppliers
Review supplier feedback and adjust designs when beneficial
Compile tooling and production cost estimates
Deliverables
Final BOM and tooling costs
Production schedules and volume pricing
Phase 7 — Tooling
Executing tooling and validating production readiness.
We manage the tooling process to ensure dimensional accuracy, performance, and repeatability before full-scale production.
What we do
Tooling kickoff and first-article (T1) evaluation
Fit, function, and dimensional validation
Final sample approval (T2) and launch support
Ongoing PO and production coordination
Deliverables
Approved pilot production samples
Quality control alignment
First article inspection
Phase 8 — Production
Delivering consistent, scalable manufacturing output.
We remain engaged through launch to ensure product quality and supply continuity.
What we do
Oversee production startup and ramp
3rd party assembly (as needed)
Coordinate shipment
Oversee logistics and shipment to final destination
Ongoing PO and production coordination
Deliverables
Finished, packaged goods delivered to your warehouse
Quality control alignment
Production launch and supply chain support
