Deliverables in the design process

At ManGo, our process begins with thorough research, where we collaborate closely with the client to understand their brand identity, target audience and market trends. Given ManGo’s involvement in various industries, we don’t confine our research to the client’s domain alone. Instead, we explore all pertinent regional and international developments. While aesthetic appeal is important, it’s crucial that the product resonates with the target audience and aligns with the right market. Our analysis involves scanning recent developments and summarizing them in a clear and concise report. We fully integrate the client’s existing knowledge to ensure our designers are as well-versed in the product environment as the client.

Mood boards serve as the vibrant blueprint for our industrial design process, offering a visual roadmap that ignites creativity and ensures alignment between our clients and our design team. These collages amalgamate colors, textures, materials and geometries, providing a holistic representation of the desired aesthetic, mood and functionality of your product. At Mango, our process begins with research and client collaboration to understand brand identity, target audience and market trends. From there, our designers curate mood boards that encapsulate these insights. These are presented to our clients for input and approval. For clients with established brand identities, we can follow their brand guidelines.

A morphological map is a structured tool we use in developments with technical challenges. It involves breaking down a system or problem into its individual functions and then systematically exploring and combining various options for potential solutions. At ManGo, our extensive database boasts over 6.000 technical solutions which is enriched by our diverse industry experience. During brainstorming sessions, our team ideas from various sectors intermingle, fostering a rich exchange of concepts. The best ideas are cross-referenced and evaluated, presented in a clear overview to pinpoint the most promising combinations. This process enables our team to explore diverse possibilities, nurture creative thinking and deliver innovative solutions tailored to meet your project’s objectives and requirements.

Often crafted by our team either during the sketch or 3D concept phase, these prototypes serve as basic, simplified representations of the product. They are created to explore and validate design concepts in the early stages of development. These prototypes are often made from simple and inexpensive materials such as cardboard, foam or clay. By quickly and affordably creating physical representations of design ideas, our designers and engineers can gather valuable input, identify potential issues and iterate on the design directions to improve their overall quality and usability.

The final 3D CAD concept presentation represents the culmination of the collaborative creative journey with our clients, where every input and insight are carefully integrated. Building upon earlier iterations and feedback, we meticulously add or finetune design details, ensuring that the final concept reflects the vision and objectives of our client. In this stage, we elevate the quality of renders even further to provide a vivid and photo realistic representation of the envisioned product.

Once the initial and simple prototypes have been tested and validated, we advance to high-end prototyping. At this stage, custom parts can no longer be produced in our workshop and are instead outsourced to professional prototype factories. These facilities use large, precise machines capable of processing materials that closely match those of the final production model. The objective is to test fit, tolerances, and mechanical performance. If the project includes electronics, we also integrate the placement of components and the circuit board for the first time, which are often still under development at this stage.

After successful prototype tests, we refine the design into the final DFMA 3D model, optimizing it for efficient production and addressing manufacturing complexities. With the DFMA model finalized, we or the client can engage with manufacturers for quotations on molds and manufacturing. Preferred manufacturing techniques are discussed and integrated into the POD as early as the first step of the development process and designs made accordingly. The selection of the most optimal techniques typically hinges on the client’s desired manufacturing price, production batch sizes and tooling budget. During DFMA, intricate manufacturing technique requirements are integrated into the 3D model. These details are time-consuming and not essential for prototyping; hence they are addressed later in the process.

These prototypes closely resemble the final product, crafted using the best prototyping methods and utilizing materials identical or similar to those used in series production. They incorporate all Design for Manufacturing and Assembly (DFMA) details into the design. Serving as the ultimate test, they guarantee that, like the preceding functional prototype, the design maintains its appearance and fulfills all intended functions. This step is always wise to execute prior to committing to the investment in often costly manufacturing toolings (molds).

In this phase of the development process, ManGo assumes the role of guardian for your product design as it transitions to the selected manufacturer or tool/mould maker. Known as the industrialization phase, this stage involves the creation of various deliverables by these third parties, which we meticulously check and document. Key deliverables include 3D CAD designs and 2D CAD drawings of moulds, test samples from the process (e.g., First-Off Tool, Second-Off Tool) and the completed moulds themselves. Test assemblies are constructed and subjected to thorough testing, while quality control documentation is prepared for future production run inspections. With these procedures and documents in hand production runs can be guided and controlled.