Custom Design Process
Our 6-Step Custom Design Process
Discovery → Prototype → Compliance → Pilot → Mass Prod → Support
Step 1: Discovery & Requirements Deep-Dive | |
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Activities: • Detailed technical consultations (voltage, environmental specs, compliance needs) • Material & component feasibility analysis • Budget & timeline alignment Deliverables: • Formal project scope document (approved by both teams) Why It Matters: • Avoids costly mid-project pivots by locking in specs early. |
Step 2: Prototyping & Proof-of-Concept | |
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Activities: • 3D CAD modeling & thermal simulations • Functional prototype assembly • Lab testing (EMI, drop/shock, ingress protection) Deliverables: • Working prototype + test reports • Design-for-Manufacturing (DFM) feedback Why It Matters: • Identifies flaws before tooling investment. |
Step 3: Compliance & Certification | |
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Activities: • Pre-certification testing (FCC/CE/UL/etc.) • Environmental stress testing (temperature, humidity, vibration) Deliverables: • Certification roadmap (with estimated timelines) Why It Matters: • Prevents delays from last-minute compliance failures. |
Step 4: Pilot Production & Validation | |
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Activities: • Small-batch assembly (50–100 units) • Real-world field testing (partner sites or controlled environments) • Refinement based on feedback (component swaps, firmware tweaks) Deliverables: • Pilot units for client validation+ performance reports • Finalized Bill of Materials (BOM) Why It Matters: • Catches scalability issues (e.g., yield rate problems) before full ramp-up. • Validates supply chain—no last-minute component shortages. |
Step 5: Mass Production & Scalability | |
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Activities: • Tooling finalization (molds, jigs, automated test fixtures) • Lean manufacturing setup (QC checkpoints at every stage) • Logistics coordination (inventory hubs, Just-In-Time delivery options) Deliverables: • First production run with full documentation (assembly guides, QC logs) • Scalability roadmap (e.g., capacity to ramp from 1K to 50K units/month) Why It Matters: • Proves we can scale without quality drops—critical for enterprise buyers. • Offers flexibility (e.g., support for regionalized production). |
Step 6: Lifetime Support & Continuous Improvement | |
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Activities: • Obsolescence management (component lifecycle monitoring, redesign alerts) • Failure analysis & root-cause fixes (RMA process integration) • Firmware/software updates (security patches, feature upgrades) Deliverables: • 5-year+ product support guarantee (extendable) • EOL (End-of-Life) notifications 12+ months in advance Why It Matters: • Reduces long-term TCO (Total Cost of Ownership)—no surprise replacement costs. • Strengthens partnerships—clients return for Gen 2 designs. |
Unlike transactional OEMs, we treat your project as a long-term collaboration—not a one-time order.
Ready to Start Your Custom OEM Project?
Get Your Free Design Audit: [ sales@benchu-group.com ]
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