Our Process

Here we like to gain an understanding of the client's vision of the product, and what they would like to achieve with it. Scheduling, markets, deliverables and the service needed from Carroll Design are all discussed.

Stepping from Phase 0, we will establish possible directions for form, function, ergonomics, component schematics and manufacturing and assembly of the product. We communicate our ideas in the form of illustrated concept drawings, CAD models and/or physical concept models.

Feedback noted from phase 1 is incorporated into the final design. The goal is to set the direction for all of the elements of the design, including form, graphics, assembly and manufacturing. This phase sometimes requires multiple iterations, depending on the complexity of the project.

Based on the concept determined at the end of phase 2, Carroll Design will develop 3D CAD files addressing the mechanical design and surface modeling, showing the overall component layout and each part of an assembly in detail. This layout would be used for quoting and to develop initial models or prototypes, and eventually for production.

ID control drawings include all exterior 3D CAD surface models and the related 2D drawings to depict finish & graphics for use in the mechanical design.

This phase can assume various formats and occur at any time during initial development phases:

1. Volume Study: Typically constructed from a dense foam or foam core, this study yields a generic representation of the proposed product. This is often done during or following Phase 2 for ergonomic or overall concept review.
2. Appearance Model: A nonfunctioning, fully detailed external model of the product, usable for product literature or trade shows.
3. Inside/Outside Model: A fully detailed and functional representation of the product, usable for product literature, trade shows, and limited initial product testing.
4. Preliminary "Bread-board" Prototypes: At any stage in the concept or detailed design development, it may be necessary to limit risk by fabricating partial prototypes of critical elements of a design solution to insure maximum functionality in the first complete prototype set.

We will quote and procure prototype component parts for assemblies. Parts will be assembled and reviewed.  Part of the review process could include testing against project requirements, preliminary requlatory testing, and end-user reviews.

Based on the review of the prototypes, we will revise the 3D CAD layout and parts. We will also update all 2D documentation to comply with your company's standards. 

Drawings, specifications, and overall 2D documentation as needed for production with 3D CAD files as the primary input to manufacturing vendors.  We design to our "Carroll Design Workmanship Standards" and provide the standards along with all pertinent documentation to all potential vendors.  While we have an in-house process and format, we are happy to provide all documentation in the format and process of our clients.  This also includes production artworks for any associated labels and applied product graphics.

Vendor liaison can occur over all phases of development. It involves a detailed search for vendors. We select only those who offer the highest standards and performance. We work with vendors at every as an engineering liaison for manufacturing start up to ensure precise and accurate manufacturing of component parts and assemblies.