From Zero to Production – Our Unique Engineering Design Process

From Zero to Production – Our Unique Engineering Design Process

What Is The Typical Engineering Design Process? 

Engineering Design is an iterative process set to identify real problems and develop and improve possible solutions. The strategy revolves around tools and unique thinking methods to reveal your situation and solutions. At Denham Products, our Engineering Design Process defines the problem your product sets out to solve, planning, testing, and modeling prototypes. 

Finished Prototype after going through Denham Products Engineering Design Process

Step 1: Identify Product Needs & Constraints

The typical Engineering Design Process at Denham Products goes like this. First, you bring your idea to us. To determine how challenging the project will be, we work collaboratively with you to choose the project’s scope. Part of understanding the project’s scope is engineering feasibility.

Engineering feasibility is the act of looking at your idea through an engineering lens. Next, we see if the concept is feasible according to the laws of physics. This step usually includes some back-of-the-napkin calculations and sketches.

The point here is to take a first-principles approach to solve and quantify your proposed solution. We also like to determine how hard your idea is to bring to market. This process allows us to say how many person-hours it will take us. Some typical questions that come up during this step are: 

  1. What problems are you trying to solve?
  2. Who cares about this problem?
  3. How many people care about this problem?
  4. How much do they care about the problem?
  5. How do you want your idea to look and feel? 
  6. What are your goals for this idea? 
  7. How fast do you want this done? 

Step 2: Research The Problem

Once we have identified your product needs & constraints, we undergo a period where we conduct an in-depth analysis of your market and see where people have previously succeeded and failed. Market Research is an essential step in Engineering Design as it dictates the rest of the process. We identify any roadblocks that may come up during the prototyping phase during market research.

Step 3: Imagine Possible Solutions

With a solid understanding of your product needs and constraints through our initial discovery call and the market research to back it up, we can start to create the solution. This initial work is usually a rough 3D model, but that is enough to bring your product in front of investors. In addition, our collaboration with you allows us to optimize your idea to attract your target audience by focusing on the unique pain points your customers are feeling.


An Example of Step 3 In The Engineering Design Process: Where The Client and Denham Products visualize the product

Step 4: Plan by Selecting A Promising Solution

Selecting one solution to focus on allows us to help you carve out a specific target market and develop a product with a high possibility of success. Since the Engineering Design Process is iterative, focusing on a different solution to the problem you want your product to solve translates into a well-rounded project.

Before moving on to the next step, Denham Products ensures that you understand why your product is best suited for this particular market and why it is different from your competitors. This step usually includes pre-prototyping or pretotyping, a new word to describe the act of creating a solution as fast as we possibly can so that we can immediately start to test its traction with the target customer. Pretotyping gives us a fast, affordable way to test usability, customer interest, and problem solution-fit. 

Step 5: Create A Prototype

Once you lock down the features you want from a pretotype, you can start prototyping. Denham Products takes the information collected from the previous steps and turns your idea into a prototype such as a 3D Print. The goal is to get something in your hands as fast as possible to empathize with the user, walk through the actions of using this prototype and note anything you want to do.

The Prototyping phase is our most collaborative and vital step in the process as it determines the sellability of your product. You can and should try to sell the prototype. Customers give much better feedback if they have a money interest in the outcome. 

A solid prototype looks and functions like your desired finished product. Our prototypes are fully functional but may have workaround solutions to valuable features. For example, the prototype may be 3D printed instead of injection-molded, or it might use a Raspberry Pi instead of a custom circuit board.

An Example of Step 5 In The Engineering Design Process: Where The Client and Denham Products create the product

Step 6: Test And Evaluate Your Prototype

Throughout the prototyping process, we advise that you reach out to manufacturers for design for manufacturing (DFM) input and determine the product’s sellability by placing it in front of your target market.

Based on the feedback that the prototype receives, it determines if the prototype is sellable, the functionality, and the overall cost of production. You can typically begin to sell your prototype to consumers and use the information to iterate your product further by leveraging this feedback.  

Step 7: Improve and Redesign as Needed

Once we reach this step, we determine how to improve your product and redesign it if needed. Ideally, after we have redefined your prototype, we take the feedback from the presales and move you to the production stage.

Denham Products aids you by selecting suppliers and working through the supplier engineering steps. Production is a significant investment, so it is essential to have developed the business side along with the product side so that you can pay back the investment it takes to go to production. For production, you need a design freeze on the model, engineered drawings and ensure the part will work as expected for its lifetime. 

We also ensure that the product design is conducive to the manufacturing technique that efficiently gets your product to market. For example, certain parts of your product are manufactured differently depending on the material and shape.

For example, a sheet metal part will be designed and manufactured differently than a plastic piece. Additionally, a plastic piece may be manufactured differently based on its body. For example, a plastic bottle is manufactured differently than a lego piece. Once we determine the manufacturing criteria, your manufacturer will require you to pay for tooling by the individual part – which is a significant investment. 

Step 8: Sales and Marketing

One of the most fundamental parts behind every successful business is sales and marketing, as, without them, it is hard to push your idea to the world. You could have a great solution to a problem, but it has no benefits if no one knows it exists. As an innovator, you have to create a marketing and sales strategy that ensures that your units sell out before developing new products and iterating on your current project. 

Now you have an idea, a solution to a problem; the next step is to determine if you want to start a business and capitalize on your newfound solution. Some questions to consider are: 

  1. Who is your target audience, and what do they care about the most? 
  2. Are you selling directly to consumers? Or are you selling to businesses? 
  3. Is your target audience willing to spend money on your product? 
  4. Are there any new markets that could benefit from your product?

It is vital to see what your ideal consumer likes and dislikes about your product so that you can use it whenever reiterating through the Engineering Design Process. We recommend tracking all feedback and tailoring future prototypes to the input. It is also ideal for developing a sales pitch and determining what is most attractive to your consumer. 

Once you’ve nailed the product-market fit, it’s time to switch from production to sales and marketing. With branding and messaging that resonates with your ideal target audience. Keep exploring, iterating, and gathering feedback. You are now on the road to success! 

After production, you have successfully created a product that the world values. You have taken a unique idea from your brain and pushed it out for others to benefit. To recap on how we help our clients at Denham Products, we usually do engineering feasibility, pretotyping, prototyping, & then production.

Start Your Engineering Design Process Today!

At Denham Products, we are working to become a platform where innovators can launch their products fast and affordably. If you have an idea, our goal is to bring it to life. So feel free to reach out.


Why Motivated Engineering Consulting Firms Like Denham Products Are Needed In Denver

Why Motivated Engineering Consulting Firms Like Denham Products Are Needed In Denver

Bringing a product to market is slow and expensive

The cost of Engineering services has always been high and has especially skyrocketed over the last 20 years as demand for technical work has increased. Many engineering consulting firms have squeezed out the typical American and Global Innovator. The traditional approach of taking an idea to market is much slower and way more expensive than it needs to be.

The enormous costs of conventional product development often bar inventors’ ideas from reaching the market. As time progresses, these costs are a massive problem because the economy stifles innovation due to the high-cost barrier to entry. That’s why we created Denham Products–to turn a napkin sketch into a physical product in a fast and affordable way.

Engineering Consulting Firm Pricing - Denham Products vs Competitors

Why Denham Products is An Emerging Leader in the Denver Engineering Consulting Firm Industry

Denham Products is an engineering consulting firm that focuses on the inventor, the entrepreneur, the hobbyist, and small business. We are breaking down the high-cost barrier and pushing more ideas to market by bringing the upfront cost of product development down and increasing the speed at which these ideas reach the market. More solutions being brought to the market is better for everyone. We have a better chance at solving our global crises if more people have a chance at fixing them. 

We primarily do this by leveraging three developing technologies: high-quality additive manufacturing, efficient computer modeling, rapid simulation software, and globally connected work from anywhere in the world. We focus on the core of the idea, and we utilize additive manufacturing to create sellable prototypes. It is our philosophy to keep it simple–focus on the need and not the want. We allow our customers to test and iterate on their ideas quickly. 

We are becoming the platform that will revolutionize the way products come to life. Our goal is to get more ideas into the physical world to solve the global problems of tomorrow, today. We specialize in bringing your napkin sketch into the physical world fast and affordably. If you have an idea, our goal is to bring it to life.

Denham Products - A Denver Engineering Consulting Firm

We’re Not Like Other Engineering Consulting Firms

As many other consulting engineering firms, we are composed of engineers with expertise in many different fields. But, here’s what makes us unique:

  • We are young and hungry engineers 
  • We work around the clock and are available anytime to chat, just give us a call or shoot us a text
  • You’ll be working directly with us as engineers for a personalized experience
  • We work fast

As a Denver consulting engineering firm, we provide helpful information for your mechanical and electrical engineering needs. By seeking out our valuable advice, you can save a lot of time, money, and energy when it comes to bringing your product to market.

How We Work


  1. Get in touch with our friendly team here
  2. We’ll contact you to discuss your awesome idea
  3. We scope the work and create a production plan for you
  4. You go on your merry way with your cool new product or continue working with Denham Products to scale up production

Typically, whenever contracted, we work as a collective to design, engineer, prototype, guide you to project completion, and even aid with the supplier selection process. This business model allows us to act as trustworthy consulting engineers as we combine our expertise with our clients in need of those services. As a result, we can guide you through your various engineering problems and develop affordable solutions. In addition, our clients generally appoint us to complete their entire project whenever it comes to activities related to different engineering fields. 


Denham Products - A Denver Engineering Consulting Firm

Choose Denham Products, we’re excited to work with you!


There is a lot to consider when awarding your project to the most qualified bidder. Whether you require a 3D design, project guidance, or something as simple as a 3D print, the deciding factors are equally important. 

When working with Denham Products, you work with engineers who have expertise in fluid product delivery and experience across multiple facets of a business. 

From our first conversation to when your project is complete, our team will be there to assist you every step of the way. We are known to go the extra mile to meet your needs and don’t stop until we exceed your expectations. We understand that every project’s backbone is a solid client-firm relationship. Therefore, we are easily accessible and eager to bring your project to life.

A significant component of our solid relationship is built on our complete honesty. We understand that there will always be inconveniences and bumps in the road with any project that may prolong our expected due date. Therefore, we are more inclined to reveal these challenges and confront them head-on throughout the project. Our full transparency allows us to collaborate and address the requirements to achieve the end goal. 

With our mission to revitalize the American and Global Innovator, we must give back to our community! Denham Products is a company that cares about the community around us! Frequently, we participate in ways well beyond our dollars, from donating to nonprofits to showing kids with dyslexia that the sky is the limit. In addition, some team members partner with their alma mater to mentor the next generation of innovative dreamers. 

If you have an idea, our goal is to bring it to life. So reach out to us, and let’s start the process of turning your vision into a reality.