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PROTOTYPING & PRODUCT DEVELOPMENT

in the U.S.—from first sketch to road-ready hardware

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One Owner

Multiple time zones, scattered suppliers, no one owning the whole prototype build.

Design for Build

Design looks great on screen, but nobody has thought about packaging, wiring, assembly.

U.S. Prototype Build

You need testable Parts in the U.S. without setting up your own facility.

Prototype to Production

You’re trying to bridge from R&D to manufacturing, but no one wants to own the messy middle.

Who This Is For & The Pain Points

End-to-End Prototyping Flow

01

Concept & Requirements

We start by turning your idea, sketch, or early CAD into a clear, shared set of requirements. Together we define what the prototype must do, where it lives in the vehicle/system, and how it will be tested.

02

Design & CAD Development

Our engineers build parametric CAD models for brackets, housings, covers, and structures that meet your specs. We keep everything review-friendly so you can comment, iterate, and lock designs fast.

03

Virtual Checks / Packaging

Before we cut any material, we verify fit, clearances, wiring paths, and serviceability in the digital model. This is where we catch headaches early—interference, access issues, and unrealistic assumptions.

04

Physical Prototyping (3D print, fab, assembly)

We translate the CAD into real parts using large-format 3D printing, light fabrication, and hand-finishing where needed. Parts are built for real handling: bolted, adjusted, and assembled like they will be on the vehicle.

05

Integration on Vehicle/ System

Prototypes are installed on your vehicle, bike, or rig with an OEM-like mindset—clean mounts, proper fasteners, tidy harness routing. The goal: test-ready hardware that looks intentional, not improvised.

06

Test Support & Iteration

We support your track, road, or lab testing and feed real-world feedback straight back into design. Short loops—adjust, re-print, re-fit—keep the prototype moving toward what actually works.

07

Pilot-Build & Manufacturing Handoff

Once the prototype is proven, we help simplify it for production with DFM/DFA input and build small pilot runs if needed. You leave with updated CAD, documentation, and lessons learned ready for your manufacturing partners.

Concept & Design Support

  • Translating rough idea, sketches, or reference parts into clear requirements.

  • Early feasibility checks (space, loads, interfaces, serviceability).

  • Design for test: making parts easy to mount, adjust, instrument, and remove.

  • Collaboration tools: online design reviews, quick turn feedback loops.

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CAD Modeling & Virtual Development

  • Parametric CAD modeling for brackets, housings, mounts, enclosures, covers, etc.

  • Packaging studies: how components, sensors, wiring, and cooling really fit.

  • Design studies for multiple variants (A/B concepts, different vehicle platforms).

  • Export formats & data handling (secure, NDA, PLM options if relevant).

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Rapid Prototyping & 3D Printing

  • Large-format 3D printing (US shop): 

    • ​​Full-scale covers, fairings, interior mockups, sensor housings.

  • Functional & visual prototypes:

    • Fit-check parts, functional brackets, dashboards, pods, etc.

  • Finishing & assembly:

    • Sanding, coating, paint, inserts, threaded bushings, basic machining/hand-finishing.

  • Camo & visual management (if you want to include it here):

    • Creating covers that hide design while preserving function and sensor performance.

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Light Fabrication, Fixtures & Mounts

  • Metal and composite brackets, sensor/fixture mounts, harness guides.

  • Basic jigs and fixtures for assembling prototypes consistently.

  • Welded frames / substructures for test mules, racks, and test rigs (if relevant).

  • Combining 3D-printed components with metal structures.

Want to try a CAD file to be built?

VEHICLE / SYSTEMS INTEGRATION & TEST--READINESS

  • Installing prototypes on vehicles, bikes, rigs (clean, OEM-like integration).

  • Routing wiring, adding connectors, strain relief, grommets (no duct-tape look).

  • Integration with your measurement / data logging / HiL / ADAS setups (only as much as fits the page).

  • Pre-test checks: fit, function, safety, documentation.

DESIGN FOR MANUFACTURING (DFM/DFA) & PILOT SUPPORT

  • Early DFM/DFA feedback: simplify parts, reduce fasteners, optimize processes.

  • Transition from 3D-printed / one-off parts to CNC, molding, stamping, etc.

  • Building small pilot batches for trials, events, demos.

  • Supporting supplier selection and CM onboarding (especially in the U.S.).

U.S.-BASED PROTOTYPING FOR U.S. & OVERSEAS COMPANIES

  • For U.S. companies:

    • Reshoring prototypes closer to your engineering and test sites.

    • Faster iteration without overseas shipping delays.

  • For international companies:

    • Local U.S. presence without building your own facility.

    • U.S. partners, U.S. test tracks, U.S. customers—all within reach.

SELECTED CASE SNAPSHOTS

  • EV prototype covers for confidential U.S. road testing

  • Cargo bike frames: from CAD to first rideable frames in 8 weeks

  • ADAS sensor integrations on pre-production vehicles

  • Interior prototype modules for show cars / press events

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HOW WE WORK

Typical starting point: CAD package, rough sketch, or reference hardware.

 

Engagement styles: fixed-scope packages, T&M for ongoing iterations, resident engineers if needed.

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Communication: one main point of contact, weekly updates, shared boards for tasks & design feedback.

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Transparency: WE ARE NOT A STAFFING AGENCY, we are a project partner.

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