Formulation
Design

Concept
Design

Configuration
Design

Parametric
Design

Detail
Design

Design
Optimisation

Regulatory
Conformity

Establish
Supply Chain

Manufacturing

Marketing
Materials

Post Market
Surveillance
Plan

Our Process

Click the hexagons to learn more about each stage

Our name exyo, short for express yourself, reminds us why we started our company. Our aim is to eliminate frustration. We want to see problem solving ideas developed into well designed products that help people to express themselves more fully! For us that means making it as easy as possible for clients to develop their ideas, turn them into market ready products, and providing support post development in manufacturing, supply chain management, and all the logistics of maintaining a device on the market.

Exyo Design Ltd is an engineering design consultancy specialising in assistive devices for independent living. Our service is a personalised one, that has at its core a user centered product development process that is directed by your goals. Clear communication, explanation, and opportunity to interact with the process at every stage are essential to our service. We’ll also seamlessly manage the transition from product development to market entry, production and post market surveillance.

Our clients said it best
“Throughout the [design] process the team at EXYO have been professional, innovative and problem solving - whilst listening to the brief. They [exyo] have a strong service user focus and have been able to translate our therapeutic intent into an end product.”
Rachael and Jayne, The Calderdale Framework

Formulation

The first stage of any project.

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Fully understand the problem. What drives the product needs? What are the key design constraints? Finding the best solution most efficiently requires taking the time to look at the whole context of a problem, and outputting a robust Engineering Design Specification. This also lays the groundwork for any required regulatory work and greatly saves on project costs down the line.


Key stage components


  • Design brief & budget
  • Timescales & quotation
  • Purpose & context
  • Stakeholder requirements
  • Regulatory strategy
  • Engineering design specification
  • Concept

    The principles behind the design.

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    What are the essential functions required to solve the problem and how can they be performed? Answering these questions allows us to show that the design problem can be solved before we go any further. It also gives us a full picture, allowing us to start to think of how these functions could fit together and which methods would work best together within a product.


    Key stage components


  • Feasability & competitor research
  • Functional analysis
  • Regulatory groundwork
  • Concept development & analysis
  • Configuration

    Form and function.

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    How can product functions fit and work together within a system? What should that system look like? How should that system be interacted with? What could the system be made from? How could the system be manufactured? Prototypes start to look and feel like products, or start to function like products. These two paths converge throughout the configuration stage.


    Key stage components


  • User interface specification
  • User interface design
  • Risk analysis & control
  • Design for function
  • Design for manufacture
  • Parametric

    Performance optimisation.

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    Refining design parameters to optimise performance. Tolerances, specific materials, finish, manufacturing processes etc. are evaluated and refined until the system meets the satisfaction requirements outlined in the formulation stage and maintained throughout the design process. Systems can then be tested to ensure they meet regulated safety standards.


    Key stage components


  • Materials specification
  • 3D CAD modelling & FEA
  • Prototyping
  • Static & dynamic testing
  • Information for safety
  • User testing
  • Detail

    Refining touches and finalising documentation.

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    Are there any minor modifications required as a response to system testing? What details, tolerances, and inspection requirements are required for batch manufacture? How will the system be packaged? Documentation for manufacturers, users, and regulators is finalised and regulatory hurdles to CE marking are addressed, clearing the way to market entry.


    Key stage components


  • Product specification
  • Detail drawings & bill of materials
  • Manufacturing specification
  • Packaging, labelling & owners manuals
  • Quality control & inspection process
  • Design Optimisation

    More detail to come...

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    Key stage components


  • Client design feedback
  • Formative user and expert evaluations
  • Risk management optimisation
  • User interface optimisation
  • Design revisions
  • Further CAD, FEA, prototyping & testing
  • Regulatory Conformity

    More detail to come...

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    Key stage components


  • Clinical & summative evaluation
  • Risk management
  • Usability engineering reports
  • Design technical file
  • Manufacturing readiness report
  • Declaration of conformity
  • Establish Supply Chain

    More detail to come...

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    Key stage components


  • Component supplier liaison - quotation
  • Manufacturing supplier liaison - quotation
  • Sample reviews
  • Supply chain contingency
  • Quality control & inspection
  • Manufacturing

    More detail to come...

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    Key stage components


  • Supplier liaison - manufacture
  • Batch size growth management
  • Supply chain optimisation
  • Stock management plan
  • Control of production quality
  • Marketing Materials

    More detail to come...

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    Key stage components


  • Technical imagery for instructions/packaging
  • Technical product photos & usability videos
  • Realistic CAD visuals
  • Regualtory guidance on marketing claims
  • Post Market Surveillance Plan

    More detail to come...

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    Key stage components


  • Product feedback capture process
  • Warranty verification procedure
  • Returns & repairs procedure
  • Incident logging
  • Critical design change triggers
  • Our Process

    Click the loop or one of the hexagons to learn more