Pilotfish helped the FahrradJäger team throughout the entire mechanical development process of INSECT.
We were there for the initial product design, detailed mechanical design, engineering, tool making and testing as well as the final manufacturing and assembly. We even helped develop INSECT’s unique lock mechanism. Our experts sourced necessary components and helped FahrradJäger find the right production partner in Asia.
The purpose of the DNA phase is to understand the user, market, and technology as well as clearly outline the product definition document (PD). In addition, we conduct qualitative user research through user observations and interviews and then develop personas and user cases. Together, the PD and user-based research result in the initial product concept ideas.
Proof of Concept
In the POC phase, we develop the working principles and test them. All critical and unknown aspects of the product have to be understood and problems must be solved before moving onto the next phase.
ID & UX Design
During the ID phase, we create the product’s appearance and user interaction. We not only make sure that the product is designed to be ergonomically friendly and visually appealing but also keep the production feasibility and cost needs in mind. By working hand in hand with engineers and production managers, we design the product to minimize the risks and costs that may occur during the production phase.
Our team of engineers designs the encasement and all details for production, including draft angles, screw bosses and ribs for assembly. The engineering work is tested with working prototypes and the final deliverables are 3D files and supporting documents ready to start tooling. Pilotfish can also manage the development of the electronics with the support of our team in Taiwan.
Tooling & Production
Pilotfish oversees all tool design and the quality control of the tool production. We diligently work with trial samples until we reach the golden sample, or in other words, the perfect set of finished parts. During the pilot run, small batches of the product are made for end users to test as well as for marketing and promotional purposes and CE/FCC certification. After the pilot run, Pilotfish manages the production of the finished, ready to sell the product.
Designing parts for efficient product assembly is a crucial consideration during hardware development. We ensure that the product is designed with the minimum number of steps on the assembly line in order to avoid tremendous costs and production delays. Although Pilotfish can design the quality control (QC) process and all necessary test jigs, we keep the process transparent. If desired, the client can always do their own QC or determine how many items we should test. We can test every item that comes off the production line or sample only a specific percentage of of the production batch.
Behind the Scenes
We challenged ourselves to design INSECT to be easily installed on the bike yet almost impossible to remove by a thief. Here is a small insight of our process.