My product development services help manufacturers, small businesses, startups and inventors take a product from an idea to a design that a factory can quote for and build. Over 15 years I’ve designed equipment for agricultural machinery, marine and electronics and lighting companies, and I bring that same practical approach to every project.
15+ years
designing products for manufacture
BEng (Hons)
Mechanical Engineering
SolidWorks
3D CAD and drawings
UK wide
remote, based in Lincolnshire
Where products go wrong
Most products don’t fail because of a bad idea. They fail somewhere between the idea and the factory floor. For example, a part that looked fine on screen turns out to need three operations instead of one. Similarly, an assembly takes twice as long to build as anyone expected. A component that worked on the prototype starts failing once it’s made in volume.
However, these problems are almost always built in at the design stage, and they’re far cheaper to solve there than once tooling has been paid for. That’s why good product development services focus on manufacture from the start. Most of my career has been spent in the space between the drawing office and the shop floor, and that’s where I can save you the most time and money.
My product development services
Concept development
At the start, the most useful thing I can do is narrow down the options. I’ll look at a few ways of solving the problem, think through how each would be made, and explain the trade offs plainly so you can decide before money is spent on tooling or prototypes.
Product design and refinement
Once the direction is agreed, the detailed work then begins: choosing materials, sizing parts, deciding how components fix together and making sure the assembly does what it should. As a result, small decisions here have the biggest effect on the final cost.
Product improvement
Existing products often have problems that only show up in production or in use. A part that is always awkward to weld, an assembly that takes too long, a component that keeps failing in the field. I’ll review the design and propose changes that are practical to introduce.
Prototyping support
A prototype should answer a specific question, so the first step is deciding what needs testing. After that, I’ll prepare the design for the right method: a 3D print to check fit, laser cut parts to prove a sheet metal design, or a fabricated prototype to test under load.
Design for manufacture
I design parts around the process that will make them. Bend radii and hole positions that suit the press brake. Weld access and distortion control on fabrications. Draft angles and even wall thickness on mouldings and castings. Sensible tolerances throughout.
Manufacturing preparation
Finally, when the design is finished, your supplier needs clear and complete information. I produce the drawings, parts lists and documentation that let them price the job accurately and make it right first time, without a string of questions going back and forth.
Product development across industries
My background is in agricultural machinery, marine equipment and electronics and lighting, alongside production and ERP management. I’ve designed sheet metal fabrications, welded assemblies, injection moulded parts, cast components and 3D printed products, and spent a lot of time around CNC machines, laser cutters, welders and welding robots. I know how each process behaves, what it costs and where it tends to cause problems.
Designed and made by Ben
Alongside client work, I also design and manufacture my own products. For instance, every one starts as an idea, is designed from scratch in CAD, tested, refined and then produced. As a result, it keeps my skills sharp, and it means I deal with the realities of making and selling a product every week, as well as designing it.
Recent design work
A selection of recent projects. You can read more on the case studies page.
C channel tabletop support
The brief was to keep a solid timber tabletop flat and rigid without visible steelwork spoiling its look. I designed a recessed steel C channel that sits into the underside of the top. It stiffens the timber and helps resist distortion while staying out of sight, and the parts were kept simple to fabricate.
Flat pack Ryobi tool holder
A wall mounted holder for Ryobi battery tools, designed as a product to sell online. The challenge was postage, as a bulky holder can easily cost more to ship than it’s worth. I designed it to pack flat and go together easily, keeping it within an economical postage size and simple to manufacture.
Who you will be working with
I’m Ben Sturgeon, a mechanical design engineer with a BEng (Hons) in Mechanical Engineering and over 15 years of experience. When you work with me, you deal with me directly from the first call to the final drawing. No account managers and no handing your project to someone you’ve never spoken to.
I like straightforward conversations and simple solutions. So if something won’t work, or will cost more than it needs to, I’ll tell you early and suggest a better way.
How my product development services work
1. Free initial call
You tell me what you want to achieve, what you have so far, and any constraints such as target cost, timescale or volumes.
2. Clear quote
I confirm the scope, what you will receive, the timescale and the price before any work starts.
3. Design and review
I develop the design and share progress at agreed points, so you stay involved in the decisions that matter.
4. Handover
You receive the final models and drawings, ready for prototyping or production.
Questions about product development services
How much will it cost?
I work at a fixed rate of £40 per hour, or I can quote a fixed price for the whole project after a free initial call. Either way, you’ll know the cost before any work starts.
How long will it take?
It depends on the size of the job. A single part can often be turned round quickly, while developing a new product normally runs over several weeks. I’ll give you a realistic timescale with the quote, and keep you updated if anything changes.
Can my idea actually be manufactured?
That’s one of the first things I’ll look at. If a design is going to be difficult or expensive to make, I’ll tell you and suggest alternatives. Designing for manufacture is the core of what I do.
Have you done this kind of work before?
Over 15 years I’ve designed sheet metal, fabricated, moulded, cast and 3D printed parts for agricultural machinery, marine and electronics and lighting products. If your project is outside my experience, I’ll say so rather than learn at your expense.
What files will I receive?
Normally 3D models in SolidWorks and STEP formats, PDF drawings ready for your supplier, and DXF files for any laser cut or sheet metal parts. If your supplier needs something different, tell me at the start.
How involved do I need to be?
As much or as little as you like. I’ll need your input at the start and at agreed review points. In between, I’ll get on with the engineering and only come back to you when a decision needs your input.
Will my idea be kept confidential?
Yes. I treat everything you share as confidential, and I’m happy to sign a non disclosure agreement before you send any details.
Tell me about your project
Fill in the form below with a few details about your product and the development services you need. Sketches, photos or existing drawings help, but they’re not essential. I’ll get back to you to arrange a free initial call.