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.

ARC Case Study

ARC™ - Asset Recharge Center

The Premier Mobile Device Management Kiosk Built for Tracking, Charging, and Securing Enterprise Handheld Devices.

An Inside Glimpse Into the Product Development of ARC's Enterprise Portable Device Charging Kiosk.

Product Design Requirements

ChargeitSpot came to Design 1st in early 2021 with an innovative product concept for an enterprise mobile device management kiosk. The product was inspired by the need for an aesthetic, locker-based, expandable device management kiosk with intelligent connectivity to track, secure, and manage employee devices. Design requirements included:

Modular design to support multiple customer types
Touch screen interface for employee self-service
Develop pre-production prototype in five months
Back-up battery to keep running during power outages
Scanner reads bar codes on employee badges and devices to track device access

Design and Engineering Challenges

Navigating the complexities of physical security, wireless connectivity, simultaneous device charging, and user compliance, the design team confronted a series of design hurdles during the ARC’s development, including:

Testing locker window size and materials to ensure WiFi 2.4, 5.0 GHz signals can work inside lockers
Using virtual thermal simulations, the team analyzed air flow dynamics, leading to an active heat dissipation design for concurrent device charging.
Modular sheet metal design to maintain cost targets, air flow, and kiosk modularity

ARC Product Results

Leveraging a blend of innovation and technical expertise, the Design 1st team guided ARC from initial design to prototype, testing, and mass production in less than a year. Since then, ARC has clinched several design accolades and secured nation-wide contracts with major enterprise customers.

From Concept to Production in Nine Months

“Design 1st helped us with every stage of the design process from creating a conceptual design to a more detailed design. From there, they even stepped in to help with engineering changes, production support, and procuring pieces for our prototype.”

Sheri Tate

SVP of Product Strategy

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Published on: October 16, 2023

Ridemaster – Motorcycle Communication

Ridemaster - Motorcycle Communication Device

Device for safe communication between motorcyclists on the road

An Inside Glimpse Into the Development of Ridemaster's Motorcycle Communication Device

Product Design Requirements

An avid motorcycle enthusiast and inventor came to Design 1st wanting to improve safety and communication during group rides. The idea was to design an interactive device where riders could communicate safely which each other while riding using a simple handlebar-mounted display.

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to help the inventor move from a product concept, through to a functional prototype, and on to manufacturing.

Product Results

Design 1st was able to provide the Ridemaster team, who did not have the expertise in packaging, materials selection or manufacturing, with a practical solution that fit both the required look and feel and could be manufactured at high volumes to attain the desired cost per unit.

Design 1st took us from idea to functional prototype and volume manufacturing in nine months

“Design 1st was a great partner to work with; they approached our project with a high degree of collaboration and provided us with several options at each decision point. They took our Ridemaster concept and turned it into something real that was both practical and had a high quality feel to it.”

Dave Gilmour,

Founder, and CEO – Ridemaster Corp.

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Published on: May 26, 2023

Heatstone – Outdoor Radiant Heating

Heatstone - Outdoor Radiant Heating

Innovative Radiant Heating Modular Patio Stone System to Melt Snow and Ice

An Inside Glimpse Into the Development of The Heatstone Snow and Ice Melting System

Background & Design Requirements

Heatstone Concepts came to Design 1st looking to bring a concept for a “new way to remove snow” to life using heated patio stones.

Engineering Challenges

Snow, water, extreme temperatures, and electrical connections posed multiple engineering challenges.

Product Results

Through creativity and technical understanding, the Design 1st team developed a manufacturable product ready for market that achieved regulatory approval.

Award-Winning Product that went From Idea to fully manufactured in under ten months

Working with their world-class engineering team, I was involved and guided throughout the patenting, design, engineering and prototyping process. With their broad range of suppliers, in-depth materials knowledge and prototyping capabilities – my product successfully achieved its regulatory approval. Beta trial units are being handled by the Design 1st New Product Introduction (NPI) team, coordinating the build with suppliers and testing. From here to market is now in sight and my business opportunity is now expanding with its potential uses in the home building and renovation industry.”

Nunzio Consiglio

Inventor and Founder, HeatStone Concepts

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Published on: May 26, 2023

Zumio – Clitoral Stimulator

Zumio - Clitoral Stimulator

World’s #1 Selling Oscillating Massager for Women

An Inside Glimpse Into the Product Design of Zumio

Product Design Requirements

Zumio came to Design 1st with an innovative idea to transfer energy using oscillation vs. vibration into the tip of an adult toy.

Engineering Challenges

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

Design, engineer, and test a patented "SpiroTip" rotating motion technology, mimicking features of an electric toothbrush
Test dozens of tip designs to concentrate sensation
Balance battery power, weight, and cost
Rotate tip at speeds up to 7000 rpm with pulsing pressure at 300rpm without stalling the motor drive

Product Results

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

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Published on: May 26, 2023

vSculpt – Pelvic Floor Toning

vSculpt - Pelvic Floor Toning

World's First Pelvic Floor Rejuvenation Device Using Infrared Light

An Inside Glimpse Into the Product Development of Joylux's vSculpt

Product Design Requirements

After spending two years developing the vSculpt, Joylux was nowhere close to manufacturing and launching the product. Joylux turned to Design 1st for help, asking for an aggressive 16-week timeline to get functional prototyping working.

Redesign the product structure and internal components for lower-cost and easier manufacturing
Deliver a fully-functional prototype for user testing
Add bluetooth connectivity to interact with App
Design packaging and help set up volume manufacturing and support regulatory approvals

Design and Engineering Challenges

Implementing Design 1st’s proven process, the team was able to overcome several obstacles to achieve medical regulatory approval and strict quality controls.

Quickly identified engineering risks and opportunities to facilitate low-cost trial units in short timeframe
How to integrate the LEDs, heat and vibration technology into the ergonomic constraints of the industrial design targets
Build low-cost demo models to test first in the lab and then with users making sure 90% of the designed could be carried over for volume manufacturing
Use silicone overmodling to seal electronics and allow light transfer without energy loss
Waterproof testing and updating design based on user feedback that met medical device regulations

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product and helped Joylux secure over $15 Million in VC funding.

Achieved both FDA and Health Canada regulatory certifications.
On-going support of volume production runs to feed sales across six different countries
The vSculpt won multiple design awards and founder & CEO, Colette Courtion was named a FemTech leader
Joylux signed an exclusive partnership with Halle Berry's Respin brand focused on women's health

Award-Winning medical device partners with Halle Berry to raise Menopause awareness.

“Design 1st understands getting high-quality products to the market quickly, while maintaining the user WOW factor. The Joylux team required an experienced, creative design-engineering team to guide us through the development and setup of our manufacturing. The Design 1st team was first class, they helped transform our technology and marketing goals into a world-class product to help women”

Colette Courtion

CEO & Founder, Joylux

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Published on: May 26, 2023

TravelWay – Lunch Box Container

TravelWay - Lunch Box Container

All-In-One lunch box container innovation

An Inside Glimpse Into the Development of TravelWay's Food Cube™

Product Design Requirements

Travelway Group came to Design 1st looking for help in developing a new line of unique innovative lunch containers to solve the common complaints associated with existing containers, including broken hinges and damage from microwave and dishwasher usage.

Develop a locking-lid with air-tight seal and slow-release hinge opening that can withstand the freezer, microwave, and dishwasher after repeat use.
Meet target product costs by develop multiple designs for review and test
Be simple-to-use, clean, and durable to withstand freezing and heating over and over.

Design and Engineering Challenges

After selecting a final design concept the engineering teams worked together on several hinge technologies that would survive the harsh environments of freezers, microwaves, and dishwashers through bench model build and test.

Prototype and test the five main components: lid, gasket seal, elastic hinge loops, rotary damper hinge
Test multiple BPA and phthalate free materials with focus on the hinge design quality to ensure product reliability over extended use in variety of applications.
Test and finalize pre-production prototype to ensure consistent quality over high yield, (100,000 plus) volume production runs to meet order demand timelines.

Product Results

Through creativity and technical understanding, the Design 1st team developed an award-winning, innovative FoodCube.

We went from product idea to 250,00 volume production in under twelve months

“Design 1st was the perfect partner fit to guide us through end-to-end development and manufacture, particularly as this was our first time taking on a fully custom product in this category”

Joe Assi

VP Sales, Travelway Inc.

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Published on: May 26, 2023

Toddler Monitor – Safety Door Sensor

Toddler Monitor - Safety Door Sensor

The World's Top Selling Toddler Monitor Device

An Inside Glimpse Into the Development of Toddler Monitor Door Sensor

Product Design Design Requirements

The Toddler Monitor co-founders came to Design 1st with a working prototype for a baby monitor and had ideas for the final design, however, needed a partner to help transform the Arduino –driven proof of concept into a child-friendly, low-cost connected device ready for mass production.

Engineering 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 Product that went From Idea to fully manufactured in under 12 months

“We couldn’t have accomplished what we have without the end-to-end services and guidance that Is provided by this team. We lucked out in finding a great partner!”

Krista Teare and Lisa Caruso

Co-Founders, ToddlerMonitor Inc.

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Published on: May 25, 2023

thinkRF – RF Spectrum Analyzer

thinkRF - RF Spectrum Analyzer

Market disrupting 27 GHz spectrum analyzer

An Inside Glimpse Into the Product Development of ThinkRF's Spectrum Analyzer

Background & Design Requirements

ThinkRF came to Design 1st to develop a robust heat-dissipating enclosure that would both safely hold the custom electronics and create a unique, branded design.

Engineering Challenges

Implementing Design 1st’s proven product development process, the team overcame several obstacles to deliver the industry-leading spectrum analyzer device.

Product Design Results

Through creativity and technical understanding, the Design 1st team developed an award-winning product that continues to be the #1 global selling spectrum analyzer.

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Published on: May 25, 2023

TabloTV – OTA DVR for Cordcutters

TabloTV - OTA DVR for Cordcutters

Disruptive over-the-air DVR that shook up the TV cord cutting industry.

An Inside Glimpse Into the Product Design of TabloTV's Over-the-Air DVR

Product Design Requirements

TabloTV chose Design 1st to transform their innovative DVR technology into an elegant design enclosure that would deal with the high heat output from advanced chipsets and stand out.

Engineering Challenges

The primary engineering challenge was how to alleviate thermal issues while maintaining a sleek, compact form factor.

Product Results

The six-month product development project resulted in a pre-production prototype ready for market launch at CES (Consumer Electronics Show) in Las Vegas.

TabloTV acquired for $14 Million by Scripps in 2023
Recognized by Forbes as one of the top ten companies reinventing the TV Industry
TabloTV built a passionate group of cord-cutting consumers with global distribution and continues to thrive today
Visit: www.tablotv.com to learn more

Award-Winning Product Acquired for $14M by Scripps

“Design 1st had the expertise to turn a concept into a unique branded look and marketable product that met our high expectations. “

Grant Hall

Founder and CEO, TabloTV

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Published on: May 24, 2023

Stanley – Pediatric Protection Bracelet

Stanley - Pediatric Protection Bracelet

RFID protection bracelet locates pediatric patients and long-term care residents

An Inside Glimpse Into the Product Development of Stanley's Pedz Bracelet

Product Design Requirements

Stanley Healthcare came to Design 1st for help with a new product concept. The requirement was to design a bracelet for tamperproof security, quick removal, and easy reattachment. Stanley required full product development support from concept design through to manufacturing.

Engineering Challenges

Implementing Design 1st’s proven process, the team overcame several obstacles to bring the final RFID bracelet design to volume manufacturing.

Product Results

Through creativity and technical understanding, the Design 1st team successfully developed the Pedz™ Tag into a wireless medical security device to protect patients.

Transforming an innovative RFID secure bracelet concept into a manufacture-ready device

“Two end users had to be accommodated – the individuals who wear the tags and the healthcare providers who use our systems. Design 1st did a superb job of balancing the end user requirements of both our products. We needed both devices to be durable and secure as well as easy-to-use, while still being attractive and comfortable to the individual patients.”