Below we list a fairly standard sequence of steps that you will probably have to go through in the course of designing and making a new product You can use it as a checklist to make sure you don’t overlook some vital step when planning the work, or when it has begun. But you may well have to depart from it in particular cases, and not all the steps will always be necessary.
Write it out clearly.State the problem, rather than specifying the product you’re aiming at, which will limit your imagination.
Specify what costs are acceptable.
Study the activity in which the problem arises, the people who will be using your product, and the environment in which it will be used. Study possible materials and methods of moulding.
Study possible materials and methods of moulding.
Look at existing products that are used to aid this activity.
Get relevant ergonomic information ,that is information relevant to the efficient carrying out of the activity, such as measurements of reach, or thrust, or frequency of use, or users’ bodily dimensions.
Find out if there is a relevant Standard.
Prepare a technical specification outlining the performance required.
Decide, as far as possible at this stage, what materials and processes could be used.
Make tests on materials and processes if necessary.
Estimate costs and confirm that they are within your limits.
Sketch possible shapes for the product
Sketch details, joints, etc, and methods of fixing typical sections, and possible assembly methods.
Decide on the most suitable design.
Prepare a general arrangement drawing.
Make a cardboard model — full-size if possible, otherwise to scale.
Test the model if possible.
Modify it if necessary.
Make detailed drawings of mouldings and moulds.
Show how mouldings are to be assembled.
Make mouldings, trim to shape and fit components.
Assemble complete product.
Test and evaluate
Test the product, using a typical operator in proposed working environment.
Photograph the product in use.
Prepare a critical report.
Suggest areas where the product needs to be changed, make drawings to show improvements, and repeat as much of the sequence as necessary from the design stage.