From CAD to manufacturing, without the late rework
You’ve got a design that works on screen. But will it actually build?
We help hardware teams catch manufacturability risks early, optimise designs, and move from CAD to prototype to manufacturing with confidence.
What we do
- If you want your product to be manufactured, not just impress in the boardroom
- If you want to avoid requotes, redesigns, and back-and-forth with manufacturers
- If your timeline actually matters and delays aren’t acceptable
See how Xynapse Labs helps bold ideas become real products, delivered faster, with leaner workflows and built to launch
Build it right the first time.
➡ Book a Call
Features
Why choose us
Manufacturing First Thinking
Design decisions are made with real production constraints in mind, so you’re not fixing problems after suppliers push back.
Proven Industry Experience
A stellar team with 20+ years across aerospace, medtech, and consumer products, where delays, rework, and failure aren’t acceptable.
Flexible, scalable pricing
Pay only for what you need. No minimums.
For longer or unpredictable work, use our Power Packs.
Power packs: 160 discounted hours over three months. Packs are service-specific. For multi-service projects, we set a blended pack at a single rate.
pricing
Three core services. One seamless workflow.
Whether you’re validating an idea or preparing for manufacturing, our team provides support where you need it most. All services are available through a 160-hour Power Pack that is valid for 3 months.
Design
Engineering design that works in production, not just in CAD or internal reviews.
Mechanical, physical product & PCB design
Assembly-ready drawings and documentation
Compliance & documentation
Simulation
Identify performance and production risks before committing to physical builds.
FEA / CFD analysis
Thermal, electrical, and lighting simulation
Injection moulding validation
Catch failure points before manufacturing
DFM Risk Analysis
Know how your design will perform in manufacturing before committing to prototyping or tooling.
A clear breakdown of manufacturability risks
Annotated visuals showing exactly where changes are needed
Practical design changes you can act on immediately
Guidance on tooling, tolerances, and assembly
TALK TO US
Want exact numbers?
We scope your project upfront, show you the full breakdown of hours, and agree before any work begins. No hidden costs. You can choose to pay through a 160-hour Power Pack, depending on what fits best.
Case Studies
Proof in action
See how we’ve helped founders and product teams turn early concepts into factory-ready designs, faster, smarter, and with less risk.
KeepBox: Smarter Returns, Less Friction
For a leading South Asian e-commerce player, we built a modular smart locker system that cut queues, eased staff workload, and simplified returns. Compact, secure, and cloud-connected, the prototype was designed and delivered in just 3 months.
Footsie: Hands-Free Foot Door Opener for Public Hygiene
At the peak of the pandemic, we created a foot-operated door opener that cut contact risk, fit most doors, and could be 3D printed on demand. Compact, durable, and ready in two weeks, Footsie won a UNDP innovation award for its impact and practicality.
Process
Our process
We keep it simple so that you can focus on the build.
1. Discovery Call
We respond within 12 working hours of your enquiry to set up a call.
You’ll speak directly with the project engineer who’ll lead your work, minimising handoffs and back and forth.
2. Scoping & Review
Your project engineer scopes the project and walks you through the estimated hours, timeline, and deliverables in a second call.
Sustainability Checks: We highlight where sustainable materials and modular design can be baked into the build.
3. Kick-off & Execution
Once approved, we invoice and share the SLA.
Once the advanced payment is paid and the SLA is signed, work begins immediately in structured sprints.
Weekly reviews keep you in the loop (daily calls can be arranged where needed).
4. Handover
You receive clean, documented deliverables for prototyping, manufacturing, or the next sprint.
FAQ
Still have questions?
We are here to answer!
When should I get a DFM risk analysis?
Before you:
- build a prototype
- send files to manufacturers
- request quotes
- commit to tooling
That’s where small design decisions become expensive.
Can’t a manufacturer tell me what’s wrong?
They can, but only after you send them the design.
At that point:
- you’re already reacting
- changes cost more
- timelines slip
We help you fix those issues before you get there.
Why not just work with a freelancer?
Most freelancers focus on making the design work.
We focus on making sure it manufactures properly.
That means:
- fewer cost surprises
- fewer redesign loops
- more predictable outcomes
Do I need all your services?
Most teams start with a DFM risk scan, then decide what needs fixing or validating next.
How do your design costs stack up?
Check your numbers in under two minutes and compare them with what similar firms get through Xynapse.