What is a product development company?

A product development company turns an idea into a manufacturable, market-ready physical product. The work spans industrial design, mechanical and electronics engineering, embedded software, prototyping, regulatory testing, and manufacturing setup. Design 1st has provided full-service product development since 1996, helping startups, OEMs, and Fortune 500 companies launch hardware across consumer, industrial, medical, and IoT categories.

What does Design 1st do?

Design 1st is a North American product development firm headquartered in Ottawa, Canada. We specialize in custom design and engineering of useful, innovative physical products. Our 36-person in-house team covers technology research, industrial design, mechanical engineering, electronics engineering, embedded firmware, prototyping, regulatory and certifications, manufacturing setup, and supply strategy. Since 1996 we have developed more than a thousand real-world products.

How does Design 1st develop products?

Design 1st uses a refined four-stage process: Concept Design, Detailed Engineering, Product Prototype Testing, and Transfer to Manufacturer. The process has been developed over 25 years and more than a thousand products. It reduces time to market and lowers development cost by up to 50 percent. Risk identification and assessment is integrated at every stage so clients have good data to make decisions.

How long does product development take?

A typical hardware product development engagement runs 6 to 18 months from concept to manufacturing-ready, depending on complexity and regulatory requirements. Consumer electronics often complete in 8 to 12 months. Medical devices typically take 12 to 24 months due to regulatory testing. Design 1st phases work into Concept Design, Detailed Engineering, Prototype Testing, and Manufacturing Transfer.

How much does product development cost?

Hardware product development engagements at Design 1st range from approximately 50,000 dollars for early-stage prototyping to more than 500,000 dollars for full development of a connected consumer or medical product. The hourly rate is 165 dollars Canadian. Project cost depends on electronics complexity, regulatory scope including FCC, CE, and FDA, and the number of prototype iterations required.

What industries does Design 1st serve?

Design 1st serves twelve markets including medical and diagnostic, mining and industrial, health and wellness, smart home and IoT, construction and tools, consumer and home, cleantech and sustainability, transport and logistics, AI devices, robotics and automation, accessibility and safety, and telecom and networking. In 2025 the team is working on 104 new products across these markets.

Where is Design 1st located?

Design 1st is headquartered at 1840 Woodward Drive, Ottawa, Ontario, Canada. The 36-person team includes industrial designers, mechanical engineers, electronics engineers, embedded firmware developers, supply strategists, and project managers, all working in-house under one roof. Design 1st serves clients across the United States and Canada and has shipped products to clients in Europe and Asia.

Archives: Portfolio

Description.

Cloud9 Technology – FinTech VoIP Phone

Cloud9 Technologies

A disruptive VoIP investment trading system big banks are betting on.

An Inside Glimpse Into the Product Development of Cloud9's VoIP System and Wideband Handset

Background & Design Requirements

Cloud9 Technologies approached Design 1st to develop a mission-critical VoIP communication system for financial traders after their initial design concept from another firm proved challenging to implement.

Cloud9 needed a complete hardware/software ecosystem, including a custom wideband audio handset and base station to integrate with its software platform for voice-enabled trading seamlessly. Key requirements included:

Custom wideband audio handset for high clarity voice communication in noisy trading environments
Clickless mute functionality for traders to seamlessly switch between conversations
Durable, lightweight handset with adjustable volume controls and optimal ergonomics
Cost-effective manufacturing strategy for sub-100k production volumes
Tactile hardware interface supporting 600+ intercom connections for trading floors
Base station with standard electrical interfaces to enable advanced features
Highly responsive controls with dual high-resolution display feedback, plus support for multiple USB audio devices and HID

Physical Design Challenges

Design 1st transformed Cloud9’s initial concept renderings into a manufactured product by solving complex physical, electronics and acoustic design challenges.

Our industrial designers, mechanical and electronics engineers collaborated to bridge the gap between visual appeal and practical functionality, ensuring the final product met both performance requirements and production constraints. Key challenges included:

Cost-driven re-design of a single large display base station concept to a dual display solution with lowest cost customized Linux OS chipset, electronics and interacting dual display drivers.
Engineered a durable, lightweight wideband audio handset with acoustic chambers, foam and grill to suppress plosive noise, optimize audio performance and ergonomics for all-day trader usage.
Design of an innovative microphone module with a near-field noise-canceling microphone and analog filter to eliminate low-frequency booming, guiding the Japan microphone manufacturer to achieve the custom solution.

Electronics Design Challenges

The Cloud9 VoIP system required sophisticated electronics engineering to deliver the high-quality audio performance demanded by traders in fast-paced environments. Design 1st’s electronics team addressed several technical obstacles while integrating with Cloud9’s software platform and accommodating the physical design constraints. Key challenges overcome included:

Developing wideband audio circuitry with codec to meet ITU telecom standards for trader communications
Engineering a "clickless" muting solution despite low voltage outputs from the initial base station design
Designing and verification of low-noise analog audio circuitry to maintain signal clarity in trading floor environments
Highly synchronized/reliable multi processor platform with OTA firmware upgrade.
Prototyping multiple iterations of the handset electronics to achieve optimal microphone sensitivity and speaker performance
Iterative Acoustic tests for performance optimizations of noise rejection, frequency response, and voice clarity across various use cases

Project Results

Design 1st delivered a complete VoIP trading system for Cloud9 through a multi-year partnership with multiple hardware iterations and hands-on manufacturing support in China. This complex project yielded impressive business outcomes for Cloud9:

Cloud9 secured $61.5 million in funding over four rounds, with investors backing both the software platform and custom hardware ecosystem
Delivered a complete hardware ecosystem including handsets, CloudHub, and Button Board solutions
Widespread adoption by major financial institutions on trading floors worldwide
Hardware ecosystem contributed significantly to Cloud9's acquisition by Symphony in 2021

From $65m Funded Startup to Global-Leading VoIP Financial Trading Platform Acquired by Symphony

“Design 1st’s designers and engineers brought a deep understanding of telecom technology, wideband audio and production development to help us develop a world-class VoIP platform for our financial trading users. On top of this, the team helped guide us through supplier selection, manufacturing, and post-launch production support”

Leo Papadopoulos

CIO and Founder, Cloud9 Technologies

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Published on: March 2, 2026

SkyX – Drone Recharging Station

SkyX - Drone Re-Charging Station

Remote Drone Garage - Aerial Mapping Pipelines and Utility Rightaways

An Inside Glimpse Into the Development of SkyX's Drone Recharging Station

Product Design Requirements

SkyX came to Design 1st needing help redesigning their remote-controlled drone recharging station. The current design cost was 2.5x the target cost and was challenging to manufacture, assemble, and transport.

Design and Engineering Challenges

To meet SkyX’s requirements, the Design 1st team chose a custom shipping container and began work on the internal design, component selection, and testing.

Design a dual-axis Gantry that could safely raise and lower to land, secure, transport and charge the UAV
Build and test a customized off the shelf hydraulic roof opening system, lift and rotation system, and programmable logic controller (PLC)
Conducted round-the-clock rapid tests during fall and winter months to ensure doors were leak-proof and inside temperatures were acceptable during the harsh freeze thaw and -30C winter weather conditions

SkyX Product Results

SkyX accepted delivery of the fully functional prototype right at their 7-month timeline and put into field use for testing. The results were a success, and SkyX began a low-volume manufacturing run to expand operations.

Design 1st designed, fabricated and tested over 150 custom mechanical parts, over 350 electronics components and sensors
SkyX raised $13.5M Series B funding following launch of their UAV recharging drone station
SkyX is accelerating global expansion of their autonomous drone system for the Oil and Gas industry

Design 1st helped us deliver an exceptional product to market

“We didn’t look at this shipping container project as ‘one and done.’ We wanted a product that could be replicated for scale and the Design 1st team has enabled us to do just. Their team’s forward-thinking approach complemented ours and this partnership resulted in a customized container that protects, charges and transports our aerial vehicles virtually anywhere around the world.”

Didi Horn

Founder & CEO, SkyX

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Published on: February 19, 2026

Calibre Bio – Wearable Breath Tracker

Calibre Biometrics

World's First Wearable for Breath Tracking Biometrics

Explore the full product development journey of the design and engineering of Calibre Biometrcs

Product Design Requirements

After interviewing over a dozen product design firms, Calibre selected Design 1st to help bring the innovative wearable breath monitor from the lab to manufacturing and launch in the marketplace.

Design and Engineering Challenges

When Calibre came to Design 1st, the first project was an R&D exercise to find out if moving laboratory sensors and monitoring equipment into a consumer wearable device was possible. Once this was confirmed the Design 1st identified and solved several major technical risks to deliver the finished device ready for manufacturing.

How to maintain 14 hours of operating battery life through repeated uses of the device
Solve the issue of air moisture condensation that would impact sensor data during usage
Calibrate sensors to measure real-time metabolic and respiratory biometrics, fifty times per second
Airflow dynamics testing was conducted for facepiece comfort at high breathing rates and detectable pressure at low breathing rates.
A testbed with mannequin heads, bellows pumps and calibrated gas inputs was designed to verify breath measurement accuracy and repeatability.
Human anthropometrics analysis of facial structures and 3D prototype & user testing for face fit was conducted, as well as rigorous user testing and rapid prototyping/bench modeling to create optimal straps

Software Development Challenges

When Design 1st began the embedded software development, the challenge was clear: replicate $100,000 worth of laboratory equipment in a $500 consumer device. The team developed custom firmware that could capture and analyze breath composition fifty times per second, transforming complex sensor data into real-time metabolic insights.

Split processing across dual core processor: Bluetooth on one, 50Hz metabolic calculations on the other, with 14-hour runtime
Developed parametric model for mixed-chamber breath analysis, achieving 80% accuracy without mechanical valves
Built calibration system using 4% CO2 and 16% O2 reference gases to correct individual unit variations
Created algorithms to adjust O2 readings between 20.7-20.9% based on altitude and temperature
Automated production testing with purpose-built controllers and dashboard visualization tools
Integrated CO2, O2, pressure, and dual humidity sensors sampling at 1Hz for metabolic tracking

Design 1st solved the complex challenge of capturing accurate metabolic data from multiple sensors while maintaining medical-grade precision in a consumer breath monitoring device through innovative firmware development and automated testing systems.

Product Results

Design 1st helped Calibre set up a robust global supply chain and manufacturing partners and move the final product to market. The result was an award-winning innovative health and fitness device that delivers on the challenging task of taking medical lab sensor equipment into a wearable device.

Creating the World's First Wearable to Unlock the Data in Your Breath

“Design 1st’s creative, product design, and mechanical engineering services are highly distinctive. The team is intelligent and experienced, and their rapid prototyping and testing capabilities played a pivotal role in shaping our groundbreaking device.”

Udi Meirav

CEO and Founder, Calibre Biometrics Inc.

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Caframo – Boat Hatch Fan

Caframo: Taku Hatch Fan

Innovative High-Powered Marine Hatch Fan

An Inside Glimpse Into the Development of Caframo's Haku Boat Hatch Fan

Background & Design Requirements

The client came to Design 1st wanting a high-powered marine hatch fan that would deliver fast, cool comfort to boaters. The fan needed to:

Product Design Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to:

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that:

Award-Winning boat fan that went from idea to fully manufactured in under 6 months

“Design 1st’s designers and engineers demonstrated the right creativity and technical understanding, managing the product design and testing process. The result is an award winning product the market has really embraced.”

Mike Tettenborn

Director of Engineering, Caframo Ltd.

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Armstrong Pumps

Re-imagining a family of commercial fluid flow products for a global brand

Learn how an 80-year global enterprise refreshed a family of intelligent fluid flow systems and products by collaborating with a product design company

Background & Design Requirements

Armstrong came to Design 1st wanting to refresh the entire product-line of industrial pumps to match their historic brand and add new connected functionality:

Refresh visual language of all equipment while maintaining engineering integrity of products.
Develop multiple concepts to convey the new Armstrong brand across the line-up of products.
Support manufacturing teams by helping design new look to reduce production costs.
Re-design collar adapter method to remove bolts, improving look and reducing costs.

Engineering Challenges

Tackling an entire product family for design revisions while maintaining product quality and reducing manufacturing costs is a massive challenge that was overcome through several activities.

Help Armstrong retrofit existing equipment with a new 'design envelope pump controller" (DEPC) solution.
Optimize Armstrong's 'foam casting' design of common parts to reduce production costs.
Build virtual models for prototype simulations using CFD analysis to understand performance of new concepts.
Build pre-production prototype of new pump equipment parts prior to volume manufacturing.

Product Results

Following a twelve-month product design program, the first new Armstrong pump equipment products began rolling off the production line garnishing strong results, including:

Revolutionizing the 100-year old method of pump collar connections with an innovative new design.
Significantly reducing overall 'foam casting' production costs of multiple parts.
Won "Smart Product of the Year" at the Pump Industry Awards in 2021.
Maintained leading fluid flow company status growing to over 1200 employees with eight manufacturing facilities.

Revolutionizing the 100-year old method of pump collar connection

“Design 1st should be commended for contributing to the overall vision of all lines of Armstrong product. The parabolic whiplash shape is coherent, innovative and embedded in the idea of science versus design”

Neil Halverson,

Design Strategist, Armstrong Fluid Technology Inc.

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Published on: January 26, 2026

Prodrive Systems – Dental Drill

ProDrive Systems - Dental Drill

ProDrive Universal High-Speed Dental Drill System

An Inside Glimpse Into the Development of ProDrive's Dental Drill

Background & Design Requirements

ProDrive Systems came to Design 1st with innovative methods to disrupt the traditional high-speed drill and needed help to finalize the design and bring the device to market.

Engineering Challenges

By following a rigorous medical development process with prototype and testing, the team overcame several tough technical challenges:

Develop test equipment to compare ProDrive dental drill to traditional methods for accuracy, speed and durability
Prototype and test the innovative turbine assembly where the chuck locks around the triangular bur
Update original design to allow for extending and locking the triangular bur for variable length cutting

Product Results

The Design 1st team helped ProDrive develop and manufacture a disruptive tool for the dentist industry that delivers superior hand piece performance, accuracy and increased cutting speed, improving the overall experience for both patients and dentists.

Developed test equipment to compare in the leading market hand pieces and conducted field tests with dentists across North America
Design robust enough to be launched internationally with ambition to be industry standard within five years
Won multiple awards for innovative dentistry products, and named a Top 10 Life Sciences Company

Disruptive dental drill innovative moved from concept to volume manufacturing

“Design 1st’s considerable design expertise and manufacturing knowledge allowed us to completely outsource our development and their one stop expertise helped us become the leading dental technology company revolutionizing our industry.”

Richard St-Pierre

President and CEO, ProDrive Systems

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lūp – Magnetic USB Cable

Lūp Cable - Self Organizing Magnetic Cable

Revolutionary flexible magnetic, self-coiling USB-C cable with fast charging

An Inside Glimpse Into the Product Design of Lūp Cable Magnetic USB-C Cord

Product Design Requirements

Aiming to revolutionize cable management with magnetic technology, Reaction Labs collaborated with Design 1st to advance their initial Lūp Cable design. The project focused on surpassing typical USB-C and Apple performance criteria while introducing a self-coiling mechanism. Product design goals and requirements included:

Engineer a cable that automatically coils using magnets and complies with strict electrical performance standards.
Ensure the cable supports high-speed data transfer and power delivery for a wide range of devices.
Adapt the cable design for efficient large-scale manufacturing while maintaining consistent high quality.
Use up to 240 ultra-fine strands per wire, each only 50 microns in diameter, to enhance flexibility and durability.

Engineering Challenges

The Lūp Cable‘s innovative design posed unique engineering challenges, particularly in integrating magnetic coiling with high electrical performance. The Design 1st team needed to ensure these features did not compromise the cable’s functionality or standards compliance. Challenges included:

Solve interference from magnetic fields affecting data transmission and electrical integrity.
Design for durability under frequent bending and coiling.
Standardize production for consistent unit quality.
Comply with USB-C and Apple power and speed standards.
Use thermal imaging to assess and optimize heat management

Product Results

Lūp Cable’s swift transition from concept to market exemplifies Design 1st’s capacity for rapid innovation and effective execution. Released in just three months, the product quickly rose to prominence on Amazon, marking a significant achievement in the competitive tech accessories market. Its user-friendly design and powerful functionality have garnered positive reviews and robust sales figures.

The quickest market launch in Design 1st history, under three months from concept to volume production and market
Quickly earned Amazon's Choice status, indicating high customer preference and satisfaction
Utilized a novel blend of rare earth particles in the internal magnet for enhanced magnetic coiling without loss of flexibility.
Collected extensive customer praise for delivering power capability, ensuring rapid charging for devices.
Lūp cable is available for purchase on Amazon

Magnetic Lūp cable moves from concept to volume production in under four months

“We recognized the inherent frustrations users face with traditional charging cables – from tangled messes to easily damaged wires. Our goal with Lūp was to address these pain points head-on. Through close collaboration with Design 1st, we were able to seamlessly translate this vision into a reality, ensuring Lūp not only meets but exceeds user expectations.“

John Hanna

Founder, Reaction Labs LLC

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Published on: April 24, 2024

General Fuel Cell

General Fuel - Aluminum Fuel Cell Innovation

Revolutionary Aluminum-Air Fuel Cell Provides Sustainable Electricity

An Inside Glimpse Into the Product Design of General Fuel's Aluminum-Air Fuel Cell

Product Design Requirements

General Fuel Systems Inc. approached Design 1st to help commercialize their aluminum-air battery, starting with a scale-down and enhancing their existing R&D technology. The goal was to refine the initial concept, complete detailed engineering, and produce a fully functional prototype, improving functionality, safety, and environmental impact.

Minimize the battery size to facilitate easier handling and transport.
Implement a modular design that enables users to easily replace or modify components such as the anode and electrolyte.
Create a user-friendly, modular battery setup allowing for quick changes in core components for on-demand power management.
Ensure the battery system meets rigorous safety protocols to prevent hazards during operation and maintenance.

Engineering Challenges

Addressing the technical complexities of miniaturizing the aluminum-air fuel cell presented a multifaceted challenge for the Design 1st engineering team. The primary focus was on maintaining high energy efficiency and user safety in a smaller form factor while also managing the intricate electro-mechanical systems and fluid dynamics required for optimal performance. Key challenges included:

Create a modular layout for straightforward maintenance and component access, maintaining structural integrity.
Control chemical reaction rates to stabilize power output and preserve anode lifespan.
Develop a failsafe control system for reliable battery activation and safe shutdown.
Optimize fluid flow to maintain electrolyte balance and ensure consistent performance.
Integrate durable electro-mechanical components like valves and pumps for smooth operation under varying conditions.

Project Results

General Fuel’s engagement with Design 1st culminated successfully with the completion of detailed engineering for the aluminum-air battery. The system’s designs underwent virtual simulation and testing, a prototype was ready for fabrication, and all essential documentation was transferred to the client to secure additional funding and industry backing in the technology.

Finalized detailed engineering designs provided a comprehensive blueprint for the aluminum-air battery system.
Validated system functionality through extensive simulations, confirming design efficacy and prototype readiness.
Compiled and handed over complete documentation, including CAD drawings and engineering specifications, for further development phases.
Positioned General Fuel to pursue additional funding and partnerships by demonstrating a ready-to-build prototype’s potential.
Aligned project outputs with industry safety and environmental standards, enhancing investor and regulatory confidence.

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Published on: April 23, 2024

Lumenera Case Study

Lumenera - Microscopy Cameras

Ongoing Design Support Paves Lumenera's Path to Mass Production Success

An Inside Glimpse Into the Product Development Support of Lumenera's Camera Product Line

Product Design Requirements

Seeking to expand their market reach, Lumenera enlisted Design 1st’s expertise to refine the design of their camera lineup for mass production. The multi-year project involved modifying six camera types to achieve large-scale manufacturing efficiency. Key design specifications included:

Redesigned exteriors for mass production efficiency.
Precision testing via automated jigs and tools.
Uniform CCD testing with integrating spheres.
Camera models updated for mass production.
Automated testing for streamlined production efficiency.

Design and Engineering Activities

Design 1st tackled tough engineering challenges to prepare Lumenera’s cameras for mass production. Their success led to a long-term partnership as Lumenera’s go-to mechanical design team. Accomplishments included:

Redesigned six camera models for scalable manufacturing efficiency.
Developed precise automated testing jigs and instruments for quality assurance.
Implemented integrating spheres for accurate CCD sensor calibration.
Launched automated accuracy tests to elevate production capacity and product reliability

Lumenera Project Results

Design 1st’s six-year collaboration with Lumenera played a crucial mechanical design role in refining and preparing their camera technology for the global market. Their work underpinned Lumenera’s continuous innovation, contributing to its acquisition by Teledyne in 2019.

Worked on and refined six key camera product groups.
Achieved cost reductions, improving Lumenera's market position.
Supported the transition of R&D projects to commercialized products.
Functioned as the key mechanical design force, boosting Lumenera’s market presence.

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Published on: March 25, 2024

Molecule – Industrial Dehumidification

Molecule™ - Atmospheric Water Generator

Lab to Marketplace Breakthrough Harvesting Drinking Water From Air

An Inside Glimpse Into the R&D Exploration and Product Development of Molecule's Innovation Material

Product Design Requirements

California-based R&D Thinktank, Molecule chose Design 1st to transform a revolutionary desiccant nanomaterial developed by the University of Limerick into a commercial prototype that absorbs moisture from air.

Design multiple experiments and prototypes to test the properties of the material for commercial use.
Create an air-to-water generation prototype in under nine months from commercial proof-of-concept testing.
Exploration and prototype testing of novel dehumidification techniques that best utilize the material.

Design and Engineering Challenges

Taking a groundbreaking nanomaterial from lab to commercially viable prototype presented a maze of design engineering challenges the teams worked through:

How to integrate the nanomaterial into standard dessicant wheel manufacturing processes, with enough robustness to withstand corrugation and bonding.
Maintain operation and robustness from 5°C to 60°C and not have the material interact with the water.
Convert the nano-material powder into various medias, such as flat sheets, reels, filters, and pellets, for real-world testing and commercial applications.

Molecule Product Results

Molecule’s R&D exploration to transform an innovative nano-material into a commercially viable product was a success. The fully functional prototype worked, and multiple commercial applications for the unique material were developed, transforming Molecule into a global leader in the water technology industry.

Acquired in 2023 by Genesis Systems, a leader in the water tech industry.
"Innovation of the Year" - Irish Laboratory Awards
Outperformed the industry-standard dehumidification material by 350% in benchmark testing.
Purchase order from the U.S. Army Corps of Engineers.

Deepest bench of technical engineering and design talent

“I did a lot of due diligence while selecting a product development company, and Design 1st had the deepest bench for technical capability. They worked on such a broad range of products with successful commercialization. Design 1st’s early efforts in prototype development helped us move from a powder substrate into a commercial product for testing.”

Kurt Francis

CTO and Co-Founder, Molecule

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Published on: November 1, 2023