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Every stage of your product,

developed under one roof.

With our in-house designers, engineers, and machinists working together from day one, issues get fixed in CAD - not discovered in production, so you get your product shipped without compromising your vision, or timeline.

 

Engineering Process

Experience the Difference

Through our work with some of the most innovative companies in the U.S., we’ve refined our iterative product development process to fully align our engineering caliber with your vision. It’s how we’ve co-created new IP and next-gen technologies you find in aircrafts, industrial engines, night vision devices, semiconductor equipment, VR devices, and possibly your own home.

Engineers discuss final product - BuddyGuard - bg corrected-1

Our process is designed to de-risk early by design.

At each stage the goal is to eliminate uncertainty. By validating assumptions through early modeling, targeted prototyping, and focused testing, we prevent late-stage surprises that cause redesigns and schedule slips.

Our process deliberately combines FEA, thermal analysis, and CAD modeling with rapid, inhouse prototyping using Carbon DLS and CNC machining. Here is how you’ll experience the collaboration:

sherpa-proprietary-way-h-1-2

three-circles

Stage 1

Alignment, Discovery, and Ideation

Before we can get there, we need to define where “there” is. That’s why we kick off every partnership with a deep dive into your objectives and requirements.

We follow this with a process of rapid ideation, which uncovers possible approaches and creates efficiencies in the work ahead. Together, we map the path forward that best aligns with your ambitions and constraints.

ideation
Screen Shot 2026-07-05 at 10.01.55 PM

three-circles

Stage 2

collaboration

In this stage, collaboration and delivery are closely intertwined. We draw on our team’s multidisciplinary expertise to explore your product’s potential from all perspectives, then create models and prototypes for us to review and test together.

Based on our insights and your feedback, we refine them through dynamic iteration that keeps your product on track toward market launch as its best possible version.

three-circles

Stage 3

Production, Support, and Corporate Memory

With in-house additive manufacturing and precision machining, we’ll guide your innovation to production. Key to supporting a new product is preserving the knowledge of its ideation, iteration, and manufacture.

Sharing this corporate memory across our team enables us to act as a seamless extension of your R&D teams on future projects. We also become an easy bolt-on resource for ongoing training and support

Let’s Start Exploring What’s Possible
production-support

Product Validation Sprint

When your company discovers an opportunity for a new product in the market, you need to understand what it will take to pursue it. The key is to reach that understanding fast, before a competitor could make your move. We can get you there with a product validation sprint. In just a few weeks, you’ll have a solid model of how your product would need to look and function, along with a map of investments and risks.

Our sprint sequence:

Product definition


Market research


design concepts


modeling / sketching


concept prototyping

Your next design challenge starts here.

 

Get in Touch
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Sherpa Design is the engineering services firm offering end-to-end product development for R&D teams and product innovators. Featuring Engineering First Teamcenter implementation and NX Training to prepare the next generation of engineers including our own.

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