Product development – Insight Aqua free

 

Water filters must meet the highest requirements, making product development correspondingly complex.

In the following text, Eugen Lietke, Head of Development, explains product development at Aqua free and the individual steps through to the finished product.

Step 1: Creation of a product requirements document

In the first step, development begins with the conception based on a product requirements document (PRD) or functional specification. Building on this, the team develops a specification. The functional specification represents the official baseline for product development.

Step 2: The concept phase

Next, the concept phase begins, in which various levels of detail are designed. This phase results in the first prototype, which is created either by 3D printing or another process. Various prototypes are produced to account for different parts or test conditions. We use two different 3D printers for this purpose.

Afterwards, a design draft is created in CAD, a computer-aided method for constructing drawings. This model is evaluated once again. Subsequently, a visually appealing functional model is developed. This model must be approved by internal or external clients.

Step 3: Tool design

The tool design phase follows. Here, various models for injection moulding or metal components are developed in coordination with the toolmaker. During coordination with the injection moulder, discrepancies may arise between the drafts and the construction, requiring intensive discussion.

Complex tools are required for products such as sterile water filters. Therefore, precise alignment at every step of product development is essential.

Step 4: Sample & tool production

In the next phase, initial samples are delivered by the injection moulder, demonstrating what can be achieved with the created tools. Continuous balancing between design and function is essential. Important aspects here are a willingness to compromise among all project partners and stakeholders. Any changes affect the entire product and require ongoing verification and testing. Tool modifications are both time-consuming and costly, which is why close, continuous alignment between client, development, and injection moulder is required.

In parallel, initial processes for tool production are developed. Likewise, a risk assessment takes place continuously through measurements, trials, and calculations. The goal is to ensure that the product functions flawlessly.

You can imagine the entire development process as a funnel: it starts very broad and becomes increasingly detailed towards the end. This is achieved through close alignment among all parties involved.

Step 5: Pre-series production

Following the completion of these phases, a initial pre-series run is produced and tested. The focus here is on product verification.

Finally, it should be noted that the project process at Aqua free represents a hybrid model – a combination of traditional and agile project management, which works very well for us.