The next stages of AION’s product design process focus on preparing the design for manufacturing (DFM) and coordinating the production setup. Our approach ensures that every product is optimized for the most efficient, sustainable, and cost-effective manufacturing process while maintaining design integrity. Not taking manufacturing into the design process can lead to unnecessarily high cost of tools, tools prone to breakage and expensive production series.
User feedback and adjustments
Before moving to manufacturing, we gather feedback on prototypes to refine the design. This iterative process allows us to resolve potential challenges early and optimize the design for manufacturability. By closely collaborating with clients, we ensure their product meets performance expectations while aligning with the realities of production.
Tailoring manufacturing to the product
AION leverages our expertise to guide customers toward the best manufacturing processes for their product’s design, volume, and budget. We work with partners to ensure high-quality production, emphasizing local manufacturing whenever feasible to reduce logistics and environmental impact.
Manufacturing processes AION can utilize
- Injection Molding: Ideal for mass production of intricate, detailed parts.
- Extrusion: Used for creating uniform, elongated components like pipes and profiles.
- Rotational Molding: Suited for producing large, hollow items like tanks and containers.
- Blow Molding: Perfect for manufacturing lightweight, hollow objects such as bottles and drums.
- Vacuum Forming: Applied for thin-walled plastic parts, like blister packaging and trays.
Each method has unique advantages depending on the design and functional needs of the product. AION evaluates all aspects to recommend the most suitable approach, ensuring efficiency and alignment with sustainability goals.
Tooling and production setup
Once the manufacturing process is determined, AION manages tooling procurement and setup. This includes ordering molds or other tools tailored to the selected manufacturing process. We handle everything from tool specifications to overseeing the first production runs, ensuring all processes are optimized for quality, cost-efficiency, and minimal waste.
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Collaboration for success
AION’s network of trusted manufacturers and recyclers plays a crucial role in realizing circular solutions. By designing with recyclability in mind, we create products that can re-enter the production cycle at the end of their life, fulfilling the promise of a sustainable, circular economy.
Our hands-on approach guarantees that every product transitions seamlessly from concept to creation, embodying the highest standards of sustainability and innovation.
