6 key steps to design and industrialize an innovative product

Industry, healthcare, sports, mobility, and connected technologies — whatever the sector, the success of an innovative product depends on a well-structured development cycle. At AQ-Tech, we guide our clients from idea to production, helping them anticipate constraints early and focus on their product’s value.

Here are the 6 essential steps we follow to design, prototype, and industrialize innovative products efficiently — a proven methodology applied in our prototyping and industrialization projects.

1. Pre-study: defining the foundation

The pre-study validates the technical, financial, and industrial feasibility of the product. This phase establishes a development plan that considers technologies, materials, manufacturing processes, cost targets, and design constraints.

Each parameter is analyzed to ensure the concept is both innovative and achievable. Technical and competitive benchmarking is key at this stage. AQ-Tech has applied this methodology across numerous projects.

2. Prototyping: bringing the idea to life

This is where the concept becomes tangible. Prototyping transforms sketches into real, testable objects. The goal is to validate a Proof of Concept (POC) and refine the design through rapid iterations of testing and improvement.

Thanks to 3D printing, machining, or vacuum duplication, functional or aesthetic prototypes can be produced within days. This allows early user feedback and even small pre-series for testing under real conditions.

Pro tip: from the very beginning, consider the product’s full lifecycle — packaging, maintenance, recycling, and logistics — to ensure a sustainable and cost-efficient approach.

3. Industrialization: from prototype to production

This stage bridges the gap between a validated prototype and a mass-producible product. The goal is to optimize design, materials, and processes to achieve the best balance between performance, cost, and lead time.

• Anticipate the entire lifecycle: manufacturing, assembly, packaging, logistics, and recycling. Design for manufacturability from day one.
• Work with the right industrial partners: electronics, plastic injection, textiles, assembly — AQ-Tech relies on a strong network of trusted partners to ensure the right expertise for each project.

Industrialization is a strategic and collaborative process. The success of this phase depends on technical precision and transparent communication between all stakeholders.

4. Pre-series and validation

When the molds are ready and components delivered, pre-series production begins. These first batches validate tooling, assembly, tolerances, and overall quality.

Launching directly into full-scale production can be risky. Producing a limited run first helps identify and correct critical issues before ramping up volume. This gradual approach ensures a smoother industrial transition.

5. Industrial transfer

Once production is stable, it’s time to take control of the process. Industrial transfer means mastering production monitoring, quality control, and traceability. It ensures that your product is consistently manufactured to the expected standards.

At AQ-Tech, we support our clients in understanding and managing their manufacturing processes. Building this knowledge empowers them to sustain product quality and efficiency over time.

6. Production and supply chain management

Congratulations — your product is ready for full-scale production! However, managing production means anticipating and adapting continuously. From supply chain to quality checks, every detail matters.

With the ongoing challenges in electronic component sourcing, production management has become more critical than ever. AQ-Tech assists many clients with production follow-up to ensure smooth operations, on-time deliveries, and continuous quality control.

Key takeaway: anticipate, plan, and secure your resources. Efficient production planning is the cornerstone of reliability and profitability.

Conclusion

Designing and industrializing an innovative product requires both creativity and technical rigor. The process is rarely linear — it involves feedback, iterations, and constant adaptation. This flexibility is what ensures the quality and success of the final product.

At AQ-Tech, we combine design, prototyping, and industrial expertise to transform ideas into reliable, scalable products. From early prototyping to industrialization and production, we’re here to help you bring innovation to life. Contact our team to discuss your project.