Product Development Process

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Design Release/ Manufacturing Support

Testing

Prototyping

Analysis

Design & Development

Brainstorming & Ideation

Business Vision

PRODIGY PRODUCT DEVELOPMENT PROCESS

NextEra Analytics Case Study

The Prodigy team supported a leading building products brand in developing a unique product identity for their new line of condensate pumps aimed at retail launch in Lowe’s.

Building Product Customer

The Prodigy team collaborated with a leading consumer goods brand on their line of vacuum cleaners to generate high-level concept idea

Consumer Goods Customer

CASE STUDIES

Over the last 12 years, Stolle has worked with Prodigy to update and improve its equipment offerings—including the design and development of entirely new can-making machines.

Stolle

Eyas kicked off project development of a new line of products supporting NICU MRI equipment.

NeoView (now Eyas)

Develop concepts of new, creative video technology that optimize compactness, robustness and manufacturability of the overall system.

Trimble

A large medical device company wanted to redesign a laser surgical system, but had multiple failed attempts over the last 20 years.

Laser Surgical System

In the medical device industry, life and performance testing are critical tools for both development and quality control. Prodigy excels at designing these types of custom devices.

Med Device

CASE STUDIES

Over the last 12 years, Stolle has worked with Prodigy to update and improve its equipment offerings—including the design and development of entirely new can-making machines.

Stolle

Eyas kicked off project development of a new line of products supporting NICU MRI equipment.

NeoView (now Eyas)

Develop concepts of new, creative video technology that optimize compactness, robustness and manufacturability of the overall system.

Trimble

A large medical device company wanted to redesign a laser surgical system, but had multiple failed attempts over the last 20 years.

Laser Surgical System

In the medical device industry, life and performance testing are critical tools for both development and quality control. Prodigy excels at designing these types of custom devices.

Med Device

CASE STUDIES

Prodigy created a successful design of the SFC Jenny series of portable fuel cells for dismounted operations.

SFC Fuel Cell

Prodigy conducted a comprehensive Modal Analysis for a leading thermowell manufacturer.

Manufacturing

VEGA wanted to develop an automated fixture that would allow the operator to select from a variety of weld recipes, perform the weld operation, and record a visual inspection of the results.

VEGA

CASE STUDIES

Through iterative FEA simulations, Prodigy was able to identify potential failure points within Mesa's design.

Mesa

Prodigy was brought on for its electrical, PCB hardware design, firmware design, and software design expertise.

Ancra

Prodigy carried the momentum of creating an initial "looks-like" prototype that secured company-wide support.

Building Products

A large medical device company wanted to redesign a laser surgical system, but had multiple failed attempts over the last 20 years.

Laser Surgical System

CASE STUDIES

Prodigy delivered a full operator interface for process guidance, welder control, and complete system management.

VEGA

Client uses this instrument in every lab and factory that develops or manufactures this product category.

P&G

The Globe Union team contacted Prodigy to develop a universal shower valve body design for the purpose of upgrading their shower offerings.

Globe Union

CASE STUDIES

Eyas kicked off project development of a new line of products supporting NICU MRI equipment.

NeoView

CASE STUDIES

EYAS NEONATAL MRI

Challenge: As a new player in the medical device space, Eyas required expert guidance to navigate the rigorous quality and regulatory standards, flexible support to scale their growing engineering team, and precise engineering to meet the operational and safety requirements of MRI systems Solution: We provided engineering expertise across multiple areas, including product design, mechanical system engineering, and prototyping, transforming Eyas' working prototype into a production-ready solution. This partnership allowed Eyas' Engineering Team Lead to focus on system-level objectives while advancing detailed product designs. Outcome: Partnering with Prodigy accelerated Eyas Medical Imaging's product development timelines while maintaining high standards of quality. This collaboration enhanced Eyas' engineering capabilities, allowing their team to explore new ideas and innovations. The products developed set a new benchmark for neonatal MRI solutions, empowering healthcare providers to deliver improved care for infants.

Outcome: Through iterative FEA simulations, Prodigy was able to identify potential failure points within the design and recommend design optimizations to lead to a more reliable design. Collaborating with Prodigy has allowed Mesa to re-introduce the foam log seal as a viable option in the marketplace and meet a tight timeline to debut the product at a trade show, to rave reviews from attendees.

MESA PROTOTYPE

Challenge: Mesa was in the process of redesigning their Foam Seal on the floating roofs of their VOC storage tanks. Floating roofs with foam log seals are a deviation from the industry standard due to longevity concerns. Through this redesign, Mesa is attempting to rebuild the rest of the industry’s trust in foam log seals, meaning extra efforts were required to challenge the design direction and increase long-term robustness of the product Solution: Prodigy initially assisted Mesa with analysis and testing of their newly proposed designs, conducting analysis on the foam to find the ideal compression, ideal foam shape/configuration, optimized the design of the bracket that holds the foam, completed an analysis to determine the ideal adhesive to bond the foam to the bracket and completed physical testing to validate.

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Client Benefits

Reliable Product Launch: Increases confidence in product readiness.​ Cost Savings: Reduces need for costly post-launch fixes.

Prodigy's Role

Comprehensive Testing: Execute performance, durability, and compliance tests.​ Iterative Refinement: Comprehensive Testing: Execute performance, durability, and compliance tests.​

Why it Matters:

Ensures Quality Standards: Verifies the product meets all specifications.​ Minimizes Post-Launch Issues: Reduces risk of failure in the field.

Objective:

testing & validation

Conduct rigorous testing to confirm performance, durability, and regulatory compliance.

Prodigy carried the momentum of creating an initial "looks-like" prototype that secured company-wide support for a fully engineered line of condensate pumps targeted for a retail launch in Lowe's into managing the complete design and development process, ultimately producing a functional prototype to validate performance prior to advancing into manufacturing and capital investment.

Building Products

Challenge: Design a rugged, compact, and lightweight fuel cell with advanced features for durability, lightness, and stealth in field combat scenarios. Solution: Prodigy designed a product capable of achieving the outlined goals of the project. Part of the process involved carrying out iterative Computational Fluid Dynamics (CFD) analyses using SolidWorks Flow Simulation to optimize the cooling system for maximum cooling and minimum heat signature detection. Outcome: Prodigy created a successful design of the SFC Jenny series of portable fuel cells for dismounted operations, a product that is still being manufactured and sold to the U.S. Military and NATO today.

SFC FUEL CELL

View Case Study

Client Benefits

Access to a Managed, Cross-Functional Team: Provides expertise across industries, offering well-rounded insights and solutions.​ Ready-for-Production Designs: Delivers fully developed products that are optimized for performance, manufacturability, and compliance.

Prodigy's Role

In-House Engineering Depth: Our team covers all aspects of development, from detailed CAD modeling and simulation to prototype creation and testing.​ Consistent Quality & Collaboration: Maintain a collaborative, client-centered approach to adapt designs efficiently, ensuring every product is ready for market.

Why it Matters:

Industry-Leading Expertise & Innovative Engineering: Prodigy’s team brings advanced skills and innovative approaches to every stage, supporting high-quality outcomes.​ Integrated Solutions: A unified approach to design, analysis, prototyping, and testing helps anticipate and resolve potential challenges early on.

Objective:

design & development

Provide comprehensive engineering expertise throughout every phase of product development, ensuring seamless progress from concept to production.

Outcome: During the process, Prodigy was able to showcase its whole system development capabilities and accelerate the process significantly faster than the client was able to internally. Prodigy demonstrated quickness of development, and flexibility in adjusting to the customer’s needs/design shifts. Budget optimization, workflow efficiencies, and accelerated timelines from Prodigy allowed for more development on the system than had been done on any of the previous failed attempts.

LASER SURGICAL SYSTEM

Challenge: A large medical device company wanted to redesign a laser surgical system, but had multiple failed attempts over the last 20 years. There were many challenges and regulatory concerns due to the fact that this machine would perform a procedure that can typically only be done once or twice in a person’s life. Solution: Prodigy engaged to develop requirements, support market research efforts, design multiple prototypes and conduct initial verification testing to ensure designs were performing as expected. This project required significant collaboration between mechanical, electrical, and software departments for this complex system. Prodigy conveyed expertise in the areas in which the customer needed the most support.

GLOBE UNION: UNIVERSAL SHOWER VALVE BODY DESIGN

Challenge: Globe Union contacted Prodigy to develop a universal shower valve body design for the purpose of upgrading their shower offerings. At the time, the aesthetics of their offerings had fallen behind the times compared to those of their competitors. Solution: One of the most exciting elements of this project involved the design and development of interchangeable components for its entire family of brands. Through interchangeable components, Globe Union could simplify its manufacturing and assembly processes and increase manufacturing efficiency—which would free up capital to improve materials quality, durability, and aesthetics. Outcome: Prodigy achieved all of the goals and parameters outlined for the Globe Union universal shower valve design project. Sold as the Gerber Treysta Valve, customers continually celebrate the valve for providing the flexibility to fit the unique requirements of each installation—saving money while reducing the time of installation.

View Case Study

Client Benefits

Consistent Quality: Ensures the final product meets design intent.​ Reduced Time-to-Market: Streamlines the path from design to production.

Prodigy's Role

Release Documentation: Provide all necessary design documents and specifications.​ Manufacturing Support: Offer guidance on tooling, materials, and processes as needed.

Why it Matters:

Smooth Transition: Helps ensure a seamless shift from development to production.​ Support Product Quality: Reduces potential production issues with on-demand support.

Objective:

design release & manufacturing support

Finalize and release design for manufacturing, providing ongoing support as needed.

View Case Study

Client Benefits

Focused Resources: Maximizes efficiency by prioritizing impactful projects.​ Reduced Risk: Minimizes scope changes and redesigns later.

Prodigy's Role

Collaborative Visioning: Work closely with clients to capture business and technical needs.​ Project Validation: Assess feasibility and alignment to prevent costly rework.

Why it Matters:

Early Alignment: Ensures focus on projects with the highest impact and ROI.​ Vetting for Value: Helps confirm we’re pursuing the right projects before development begins.​

Objective:

Business vision & requirements setting

Define the strategic vision and core requirements, aligning on what success looks like.

EYAS NEONATAL MRI

Challenge: As a new player in the medical device space, Eyas required expert guidance to navigate the rigorous quality and regulatory standards, flexible support to scale their growing engineering team, and precise engineering to meet the operational and safety requirements of MRI systems Solution: We provided engineering expertise across multiple areas, including product design, mechanical system engineering, and prototyping, transforming Eyas' working prototype into a production-ready solution. This partnership allowed Eyas' Engineering Team Lead to focus on system-level objectives while advancing detailed product designs. Outcome: Partnering with Prodigy accelerated Eyas Medical Imaging's product development timelines while maintaining high standards of quality. This collaboration enhanced Eyas' engineering capabilities, allowing their team to explore new ideas and innovations. The products developed set a new benchmark for neonatal MRI solutions, empowering healthcare providers to deliver improved care for infants.

Outcome: Within a year, Stolle had a necker machine prototype to display at the 2018 Cannex trade show By this time, Stolle has installed more than a dozen Prodigy-designed necker machines around the world with a backlog of several more.

STOLLE MACHINERY: BEVERAGE CAN MAKING EQUIPMENT DESIGN

Challenge: Stolle wanted to build its own necker machine to add to their competitive advantage and provide a complete in-house solution. Wanted a necker machine that was modularly flexible and substantially faster than those of competitors. - Solution: Prodigy developed a necking machine capable of operating at 4,800 cans per minute—compared to the 3,400 per minute speed of competing machines. The machine was designed to be modular—allowing operators to configure the machine to produce a wide variety of beverage can sizes, from 6 ounces to 32 ounces and larger.

View Case Study

Client Benefits

Early Product Testing: Identifies adjustments before full production.​ Informed Design Decisions: Incorporates feedback to refine design.

Prodigy's Role

Prototype Creation: Build physical models for functional testing.​ Client Feedback Loop: Collaborate with clients to gather and implement feedback.

Why it Matters:

Hands-On Validation: Provides tangible feedback on design performance.​ User Testing Opportunity: Allows for real-world usability insights.

Objective:

Prototyping

Build initial prototypes to evaluate design and functionality.

Medical Device

In the medical device industry, where failure is not an option, life and performance testing are critical tools for both development and quality control. Prodigy excels at designing these types of custom devices to meet the demanding needs of this industry. Our insight, experience, and advanced knowledge of applied physics enables us to better simulate actual conditions so that test results more accurately reflect the real-world. In this example, challenges include sealing, corrosion resistance, and temperature control of heated and circulated saline, as well as accurately simulating a bio-mechanical action that had yet to be effectively reproduced. Other features include network connectivity, pressure sensing and stepper motor control of two independent banks of 16 test samples, as well as LabView programming for all controls and user interface. As a testament to Prodigy’s innovation throughout the product development process, we were instrumental in the original development of this unique implant product that saves surgeons’ time, and we invented the testing technology and instrument used to aid its refinement and quality assurance.

Outcome: The Ancra AutoDeck reduces freight operators’ damage claims up to 50% and increases load efficiency by 30% - all while improving materials handler safety. The automated decking system results in increased cargo cubic capacity and equipment utilization over integrated manual decking systems.

ANCRA AUTODECK

Challenge: Ancra Cargo aimed to find a solution for freight shippers to increase efficiency in loading while also improving safety for the user. Freight operators using manual decking struggled with damages from over stacking, inefficient space utilization, and limited safety precautions. Ancra envisioned an automated decking system that could revolutionize the industry, but lacked the specialized electrical engineering resources to drive this effort internally. Solution: Prodigy was able to seamlessly integrate its electrical engineering expertise into Ancra’s core competencies to help develop the revolutionary AutoDeck system. Prodigy’s capabilities in PCB hardware design, firmware design, and software design helped increase Ancra’s speed to market and cement their edge over the competition.

Prodigy conducted a comprehensive Modal Analysis for a leading thermowell manufacturer, examining vibrational responses across various lengths to define a "keep-out" range where natural frequencies approached the vortex shedding frequency. Given the high-temperature conditions, material properties were adjusted to accurately reflect temperature-dependent behavior. This analysis informed a successful re-design, ultimately leading to a streamlined product launch.

Manufacturing

The Prodigy team collaborated with a leading consumer goods brand on their line of vacuum cleaners to generate high-level concept ideas addressing specific product challenges in a fast-paced, sprint-style process. Each day began with a focused briefing on a key issue, followed by intensive ideation sessions throughout the day. The team would reconvene at the end of each day to distill ideas and select the most promising concepts for further development. This approach enabled the client to rapidly explore a targeted solution set for critical product challenges, accelerating their development cycle and guiding actionable engineering decisions.

Consumer Goods

Next Era

IoT

NextEra Analytics requested Prodigy support the design and development of an electric meter attachment that can capture the reading at a set interval and send to a cloud database. Prodigy developed the existing proof of concept prototype into a feasible product and created 10 functioning units for pilot to inform future development decisions.

Outcome: Within a year, Stolle had a necker machine prototype to display at the 2018 Cannex trade show By this time, Stolle has installed more than a dozen Prodigy-designed necker machines around the world with a backlog of several more.

STOLLE MACHINERY: BEVERAGE CAN MAKING EQUIPMENT DESIGN

Challenge: Stolle wanted to build its own necker machine to add to their competitive advantage and provide a complete in-house solution. Wanted a necker machine that was modularly flexible and substantially faster than those of competitors. - Solution: Prodigy developed a necking machine capable of operating at 4,800 cans per minute—compared to the 3,400 per minute speed of competing machines. The machine was designed to be modular—allowing operators to configure the machine to produce a wide variety of beverage can sizes, from 6 ounces to 32 ounces and larger.

CUSTOM MEASUREMENT MACHINE

Challenge: When companies make claims against their competitors regarding performance, especially in consumer categories worth billions per year, they need ironclad test data to support them, or face potential lawsuits unprotected. Solution: In this case, the client needed an instrument that was more precise, repeatable, reliable, and customizable than currently available instruments, while also providing a method that better emulated real-world usage. Outcome: Prodigy exceeding hard and soft requirements that included reduction of parts, ease of use, ease of maintenance, and ease of repair. The client uses this instrument in every lab and factory that develops or manufactures this product category.

Dual Positioning Engine for Trimble Layout Tool

Challenge: Modern building designs are created using advanced software, but often lack coordination between different trades, leading to conflicts and outdated blueprints on job sites. This results in time-consuming manual layout processes and frequent rework, causing delays and frustration. Solution: Develop concepts for creative packaging alternatives for the Trimble Layout Tool head module that optimizes compactness, robustness and manufacturability while utilizing the existing part catalog when prudent. Approach:

• Requirements gathering & Ideation
• Concept development & refinement
• Alpha prototype build

View Case Study

Client Benefits

Diverse Solution Options: Access to a range of vetted ideas tailored to client needs.​ Informed Decision-Making: Confidence in selecting concepts with the highest potential for success.

Prodigy's Role

Collaborative Ideation: Facilitate sessions to explore diverse, innovative solutions.​ Concept Evaluation: Use feasibility analysis to assess each idea for practicality, cost, and alignment with project goals.

Why it Matters:

Creative and Practical: Balances brainstorming with feasibility to focus on ideas that are both innovative and achievable.​ Saves Time & Resources: Ensures only the strongest, most practical concepts move forward, avoiding costly pivots later.

Objective:

ideation and concept feasability

Generate innovative ideas, then evaluate and select the most viable concepts for development.

The Prodigy team supported a leading building products brand in developing a unique product identity for their new line of condensate pumps aimed at retail launch in Lowe’s. After understanding the client’s product requirements and desired aesthetic, Prodigy quickly created thumbnail sketches to solidify the creative direction. Once aligned, the top concept was selected for CAD modeling and prototyping, enabling internal teams and key customers to visualize the product and secure buy-in prior to full engineering development.

Building Products

Medical Device

In the medical device industry, where failure is not an option, life and performance testing are critical tools for both development and quality control. Prodigy excels at designing these types of custom devices to meet the demanding needs of this industry. Our insight, experience, and advanced knowledge of applied physics enables us to better simulate actual conditions so that test results more accurately reflect the real-world. In this example, challenges include sealing, corrosion resistance, and temperature control of heated and circulated saline, as well as accurately simulating a bio-mechanical action that had yet to be effectively reproduced. Other features include network connectivity, pressure sensing and stepper motor control of two independent banks of 16 test samples, as well as LabView programming for all controls and user interface. As a testament to Prodigy’s innovation throughout the product development process, we were instrumental in the original development of this unique implant product that saves surgeons’ time, and we invented the testing technology and instrument used to aid its refinement and quality assurance.

View Case Study

Client Benefits

Reduced Risk of Failure: Confirms that designs are robust before prototyping.​ Efficient Resource Use: Saves time and costs by addressing potential issues early.

Prodigy's Role

Technical Simulations: Perform simulations to ensure the design meets real-world demands.​ Refinement Suggestions: Propose improvements based on simulation results.

Why it Matters:

Quality Assurance: Identifies and resolves design weaknesses early.​ Cost Savings: Minimizes risks and unforeseen changes in later stages.

Objective:

engineering analysis & simulation

Validate design performance through analysis (e.g., structural, thermal) to preempt issues.

Outcome: During the process, Prodigy was able to showcase its whole system development capabilities and accelerate the process significantly faster than the client was able to internally. Prodigy demonstrated quickness of development, and flexibility in adjusting to the customer’s needs/design shifts. Budget optimization, workflow efficiencies, and accelerated timelines from Prodigy allowed for more development on the system than had been done on any of the previous failed attempts.

LASER SURGICAL SYSTEM

Challenge: A large medical device company wanted to redesign a laser surgical system, but had multiple failed attempts over the last 20 years. There were many challenges and regulatory concerns due to the fact that this machine would perform a procedure that can typically only be done once or twice in a person’s life. Solution: Prodigy engaged to develop requirements, support market research efforts, design multiple prototypes and conduct initial verification testing to ensure designs were performing as expected. This project required significant collaboration between mechanical, electrical, and software departments for this complex system. Prodigy conveyed expertise in the areas in which the customer needed the most support.

Dual Positioning Engine for Trimble Layout Tool

Challenge: Modern building designs are created using advanced software, but often lack coordination between different trades, leading to conflicts and outdated blueprints on job sites. This results in time-consuming manual layout processes and frequent rework, causing delays and frustration. Solution: Develop concepts for creative packaging alternatives for the Trimble Layout Tool head module that optimizes compactness, robustness and manufacturability while utilizing the existing part catalog when prudent. Approach:

• Requirements gathering & Ideation
• Concept development & refinement
• Alpha prototype build

VEGA MEASUREMENT MACHINE

Challenge: Vega wanted to develop an automated fixture that would allow the operator to select from a variety of weld recipes, perform the weld operation, and record a visual inspection of the results. Designing within the weld field presented challenges due to high-frequency noise interference with electronic control devices. Solution: VEGA chose Prodigy based on their local proximity, price value, and overall approach. Prodigy began by capturing requirements before moving on to concept development, followed by machine design & build, software development, debug, operational documentation, system review, installation at customer site, and follow up support. Outcome: Prodigy exceeding hard and soft requirements that included reduction of parts, ease of use, ease of maintenance, and ease of repair. The client uses this instrument in every lab and factory that develops or manufactures this product category.