A consultation is the starting point of the industrial product development process and includes the following key elements.

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Industrial Product Development Services-Design, Prototype, Testing

Design & Development

The first thing our industrial design team does when developing a new product is meet virtually or face-to-face with the customer to discuss all expectations and bring new ideas to the table. We take the time to understand the customer’s vision and address any initial concerns.

Define Requirements

Industrial product development requires designers and engineers to determine all necessary components a product will need throughout the manufacturing process, from the initial design concept through the delivery phase and end-use. External vendors and supply chain partners should be part of the discussion to ensure effective communication.

Identify the Business Case

Creating a strategic plan for custom product development helps reduce the time it takes to get the product to market, lower costs, and increase product value. Developing a new product can involve enhancing the benefits and functionality of an existing product or creating a new engineered-to-order product to meet the needs of a specific application.

The following three components are essential to making a compelling business case and ensuring a successful product launch:

  1. Description of the Product: This is a thorough explanation of the proposed product, including its purpose, market drivers, technical specifications, competitors, barriers, and other factors.
  2. Justification of the Product: Determine the market size and potential of the product as it relates to the total addressable market. Product justification also includes an analysis of the served available market in which the new product will compete, as well as revenue potential and a defined pricing strategy.
  3. Project Plan: Determine the criteria for manufacturing and technical feasibility. Consider the risks, CAPEX requirements, timings, and costs for each stage of the production process.

Once the consultation process is finished, Carolina CoverTech will assist with designing the product. Our experts will take the initial sketches, transforming them into drawings and an initial early stage prototype of the end product. This phase helps determine the product’s final appearance, how it will feel, and how customers will interact with it. Our industrial design team will develop concept designs and brainstorm ideas to meet the specific application requirements, ensuring the product is attractive to potential customers.


Industrial product designers bring your product idea to life using 2D computer-aided design (CAD) software, creating digital sketches and concepts. These sketches will allow all parties to visualize the final product and refine its specifications so that it meets its intended functionality and aesthetic goals. The computerized nature of the CAD drawing helps reduce the risk of errors, as a flawed conceptual design can fail the entire project.

At this stage, customers can request modifications or changes and choose the direction of the overall project. Once a customer approves the initial 2D CAD drafts for the final product, the industrial design team imports the sketches into a 3D design software program that creates realistic 3D models of the product.

3D Rendering

Three-dimensional depictions of the final product exceed the visualization capabilities of 2D modeling, allowing for a realistic view of the end result. Customers can rotate the model, viewing the product from any angle, and make any final changes before the prototyping process begins. 3D renderings of the final product can also be used in promotional materials to pique consumer interest long before production begins.

The next step is to create a prototype as similar to the final product as possible. This crucial step in the process allows designers one last chance to see if the concept works and confirm its capability of becoming a fully functional product. This phase brings credibility and value to the new product and must occur before advancing to large-scale manufacturing.

At Carolina CoverTech, we create various types of prototypes depending on the nature of the product, its intended use, and customer specifications.

Visual Prototype

A visual prototype demonstrates the aesthetics of a product, giving customers a better idea of the size, shape, and feel. While it is the fastest and easiest prototype to create, there are no working parts, and it does not demonstrate functionality. Prototyping materials generally consist of more cost-effective materials that may be painted to simulate the final appearance and texture of the end product.

Proof-of-Concept Prototype

This type of prototype focuses on testing the final product to ensure adequate functionality. Unlike a visual prototype, it contains some working parts to test a specific aspect or general idea to determine if a product works. By identifying existing problems and areas of concern, the design team can make the necessary adjustments and ensure the full functionality of the finished product.

A proof-of-concept prototype typically does not look exactly like the end product and can lack some of the details included in the design. It consists of cheaper materials for presentation purposes only.

Scale Prototype

A smaller-size representation of the design can be more effective than creating a full-size replica. A scale prototype proves especially useful when 3D product visuals are not strong enough to convey an idea. A scale product consists of similar materials used in a visual prototype and, depending on the product type, typically lacks full functionality.

Functional Prototype

A functional prototype focuses on the functionality and design of the final product. It is the most detailed of prototypes, looking and feeling almost identical to the finished product. Functional prototypes also better approximate actual production costs, allowing customers to adjust pricing as needed before manufacturing begins.

Once all prototypes have received final approval, field testing begins. Functionality errors or design flaws not detected earlier during development can be caught during this phase and give designers one last chance to optimize the design. Performing final testing further reduces the problems that may arise later in the manufacturing process.

Products We Have Helped Create

Carolina CoverTech has helped develop a wide array of products for applications that include but are not limited to:

  • Cable reel covers
  • Biomimicry Wound Care and Athletic recovery boots and sleeves
  • Environmental Secondary Spill Containment devices
  • Leak Diversion and capture products
  • Covers for utility vehicles
  • Rear bag cover for golf carts
  • Disposable isolation gowns

Contact Carolina CoverTech for Industrial Product Development Services

Since 1858, Carolina CoverTech has been an industry leader in developing and manufacturing products that protect, cover, contain and enclose. We specialize in producing and engineering products that require air-tight, flexible, durable, and weather-resistant properties.

Contact us today to learn more about how our industrial product development services can help your company meet the specific demands of your next project.

Custom product development combines the creative process of designing a new product idea with complex data analysis to ensure a successful launch. Understanding the stages of industrial product design and development can help customers introduce a new product that meets their business goals as well as their customers’ needs.

No matter how good a product is, it won’t attract attention and sell well in the intended market unless companies follow a series of detailed, deliberate steps. This industrial product development guide details Carolina CoverTech’s new product development services to help customers understand our processes and how to ensure a successful new product launch.