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FROM SKETCH TO FINAL PRODUCT

Eker Express Line is our process model developed through our 30 years of experience in developing a great variety of products in different market segments.

Our process model fits for small start-ups or large enterprises and is adapted to fit every project.

The continuously faster change of the market, demands shorter development time to reach the market opportunities. Our process model meets this demand! By having the in-house interdisciplinary teams working tight together, using the right tools, having the right engagement, and focus on efficiency, we manage to run several disciplines in parallel,

-and save time and cost!

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THE EKER PROCESS

The Eker Process is our process model developed through our 30 years of experience in developing a great variety of products in different market segments.

Our process model fits for small start-ups or large enterprises and is adapted to fit every project.

The continuously faster change of the market, demands shorter development time to reach the market opportunities. Our process model meets this demand! By having the in-house interdisciplinary teams working tight together, using the right tools, having the right engagement, and focus on efficiency, we manage to run several disciplines in parallel,

-and save time and cost!

Pre-project

Understanding the drivers, demands, and restraints of the product are crucial to being able to run an efficient development process. The pre-project phase focuses on gathering and producing data that will be a solid framework for decision making for our client and our project team. By identifying critical factors that will have an impact on complexity and time, we ensure that the path we choose gives us the fastest time to market. Defining the basic product specification, unique selling point (USP), legal requirements, cost analysis, market price, volume aspects and business opportunities, creates a framework for the client’s decision-making process.

Our tools: A bunch of experience, SkunkWorks, Conceptual mechanics and models, Planning, Legal requirements, Design philosophy, Hand sketching and CAD surfacing.

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Pre-project

Understanding the drivers, demands, and restraints of the product are crucial to being able to run an efficient development process. The pre-project phase focuses on gathering and producing data that will be a solid framework for decision making for our client and our project team. By identifying critical factors that will have an impact on complexity and time, we ensure that the path we choose gives us the fastest time to market. Defining the basic product specification, unique selling point (USP), legal requirements, cost analysis, market price, volume aspects and business opportunities, creates a framework for the client’s decision-making process.

Our tools: A bunch of experience, SkunkWorks, Conceptual mechanics and models, Planning, Legal requirements, Design philosophy, Hand sketching and CAD surfacing.

Concept

The Concept phase is where we develop the mechanical and design concepts. We proof the product idea by building «Proof Of Concept» models, for verification, enabling us to proceed with greater knowledge and speed into the development process.

The design concept is created by using input from the pre-project phase and searching for the right choice of materials and production processes suitable for the defined market and users. The aesthetic language shall express the capabilities of the product. It all comes together in placing the final product in front of the competitors.

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Concept

The Concept phase is where we develop the mechanical and design concepts. We proof the product idea by building «Proof Of Concept» models, for verification, enabling us to proceed with greater knowledge and speed into the development process.

The design concept is created by using input from the pre-project phase and searching for the right choice of materials and production processes suitable for the defined market and users. The aesthetic language shall express the capabilities of the product. It all comes together in placing the final product in front of the competitors.

Development & Design

3D surfacing combined with digital sketching ensure optimal design control and a safe and fast design process. The correct product design is created in 3D CAD surfacing with complete control of the internal mechanics. The design and mechanics can easily be verified through concept prototyping in our extensive in-house prototyping facilities.

We design beautiful products that the users value.

Our team of designers creates and refines the right DNA and design philosophy for the product. Values are assigned for user interaction, physical dimensions and everything in between, to ensure that the product design is aesthetic, functional and robust.

Our tools: 3D design surfacing, Digital sketching, Rapid Prototyping, Product Graphics.

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Development & Design

3D surfacing combined with digital sketching ensure optimal design control and a safe and fast design process. The correct product design is created in 3D CAD surfacing with complete control of the internal mechanics. The design and mechanics can easily be verified through concept prototyping in our extensive in-house prototyping facilities.

We design beautiful products that the users value.

Our team of designers creates and refines the right DNA and design philosophy for the product. Values are assigned for user interaction, physical dimensions and everything in between, to ensure that the product design is aesthetic, functional and robust.

Our tools: 3D design surfacing, Digital sketching, Rapid Prototyping, Product Graphics.

Rapid prototyping and reverse engineering

Building full-scale prototypes allow us to verify the product design on form, fit, and functionality. At the same time, the team can do mechanical verification, product and user tests, legal testing, build showcase models, create packaging, and do product graphics at an early stage.
Reverse engineering by 3D scanning enables us to digitize shapes or verify geometry on produced parts.

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CMM Scanning center

We use 3D scanning for reverse engineering, and transforms physical components or hand-crafted shapes, into digitized shapes. We 3D scan small, high tolerance parts such as optical interfaces, or larger size products like cars, boats and airplanes. The digitized shapes are converted from point-clouds into readable 3D-files for the engineering and product development team. By using CAD Compare we can easily compare a physical model against the 3D model and find deviations on geometry that usually are  impossible to discover.

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CNC machining

Our CNC milling machines creates parts with high finish and high tolerance demands. Plugs and molds for parts in materials such as carbon- and glass- fiber can be manufactured directly. Our small-scale 5-axis CNC milling machine, can do parts in Al and Mg with the sizes 400 x 400 x 300 mm. The large-scale 3-axis CNC milling machine, can do parts in PUR and soft materials with the sizes 6000 x 3000 x 1200 mm, and the even larger 5-axis CNC milling machine, can do parts in PUR and Al with the sizes 10000 x 4000 x 3000 mm. This CNC machining centre can deliver a broad span of products and gives us the possibility to manufacture high quality molds – or composite tool plug-sets within a short time frame.

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Vacuum casting

MCP Vacuum casting allows us to manufacture functional prototypes in small series of either handmade models or 3D printed models in silicone, hard plastic, or rubber. These casted parts are used for preproduction, verification purposes, exhibitions, and pre-launch of the product.

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3D printing

3D printing of great value to our process, and helps us verify the visual design and the mechanical functions of the product. We have an in-house 3D printer, or we use partners with great quality, short lead times and with the latest technology of materials and methods.

PROTOTYPING

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CMM Scanning center

We use 3D scanning for reverse engineering, and transforms physical components or hand-crafted shapes, into digitized shapes. We 3D scan small, high tolerance parts such as optical interfaces, or larger size products like cars, boats and airplanes. The digitized shapes are converted from point-clouds into readable 3D-files for the engineering and product development team. By using CAD Compare we can easily compare a physical model against the 3D model and find deviations on geometry that usually are  impossible to discover.

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CNC machining

Our CNC milling machines creates parts with high finish and high tolerance demands. Plugs and molds for parts in materials such as carbon- and glass- fiber can be manufactured directly. Our small-scale 5-axis CNC milling machine, can do parts in Al and Mg with the sizes 400 x 400 x 300 mm. The large-scale 3-axis CNC milling machine, can do parts in PUR and soft materials with the sizes 6000 x 3000 x 1200 mm, and the even larger 5-axis CNC milling machine, can do parts in PUR and Al with the sizes 10000 x 4000 x 3000 mm. This CNC machining centre can deliver a broad span of products and gives us the possibility to manufacture high quality molds – or composite tool plug-sets within a short time frame.

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Vacuum casting

MCP Vacuum casting allows us to manufacture functional prototypes in small series of either handmade models or 3D printed models in silicone, hard plastic, or rubber. These casted parts are used for preproduction, verification purposes, exhibitions, and pre-launch of the product.

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3D printing

3D printing of great value to our process, and helps us verify the visual design and the mechanical functions of the product. We have an in-house 3D printer, or we use partners with great quality, short lead times and with the latest technology of materials and methods.

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3D CAD Engineering

Our 3D CAD systems allow us to do design and complex detailed engineering at high speed, with great precision. The 3D system gives us complete control of all the components in the product assembly, and with the belonging PDM system, we have strict control of all the versions and revisions on pre-released and released levels. Our skilled CAD-engineers are highly trained in different 3D systems, with Advance Part & Assembly Design, Advanced Surfacing, and even Class-A Surfacing.

3D CAD Tools: NX – Catia V6 •Solid Works • ICEM Surf • Autodesk Inventor  • Autodesk PDS

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Rendering & Animation

Rendered 3D models and animations are developed from the early concepts, to the product development phases, and through to the product market launch. In the conceptual phase we visualize several concept models, and in the development phase we visualize the product for internal use, for use in web, marketing and PR related material. The Animations are often used in technical, or sales presentations of the mechanical solutions as well as the esthetical design.

Rendering Tools: 3D Studio Max • Catia V6 • Solid Works 2016 • KeyShot • Autodesk PDS

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VR Lab

In our Virtual Reality Lab the designers, engineers, and clients can experience the product in real size and in the right environment already in the concept phase. We have created our own software for visualizing the design and try out practical functions and space in the Eker Virtual Reality lab. We have added functions and functionality to provide a solid experience and to provide a powerful tool for the development team and the customers. The VR user gets a realistic experience and triggers immediate feedback useful for the ongoing product development process.

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Simulation

We utilize specialized simulation software to gain in-depth insight into our product’s performance. It may be with the aim to gain efficiency, or to optimize products with high performance weight and strength requirements. The simulation based design approach gives us the opportunity to explore a wide range of design variations throughout the development process to make sure that we deliver highly competitive products.

Simulation tools: Ansys, Numeca, Solidworks Simulation, simFlow

Engineering

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3D CAD Engineering

Our 3D CAD systems allow us to do design and complex detailed engineering at high speed, with great precision. The 3D system gives us complete control of all the components in the product assembly, and with the belonging PDM system, we have strict control of all the versions and revisions on pre-released and released levels. Our skilled CAD-engineers are highly trained in different 3D systems, with Advance Part & Assembly Design, Advanced Surfacing, and even Class-A Surfacing.

3D CAD Tools: Catia V6 • ICEM Surf • Solid Works 2016 • Autodesk Inventor • NX 11 • Autodesk PDS

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Simulation

We utilize specialized simulation software to gain in-depth insight into our product’s performance. It may be with the aim to gain efficiency, or to optimize products with high performance weight and strength requirements. The simulation based design approach gives us the opportunity to explore a wide range of design variations throughout the development process to make sure that we deliver highly competitive products.

Simulation tools: Ansys, Numeca, Solidworks Simulation, simFlow

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VR Lab

In our Virtual Reality Lab the designers, engineers, and clients can experience the product in real size and in the right environment already in the concept phase. We have created our own software for visualizing the design and try out practical functions and space in the Eker Virtual Reality lab. We have added functions and functionality to provide a solid experience and to provide a powerful tool for the development team and the customers. The VR user gets a realistic experience and triggers immediate feedback useful for the ongoing product development process.

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Rendering & Animation

Rendered 3D models and animations are developed from the early concepts, to the product development phases, and through to the product market launch. In the conceptual phase we visualize several concept models, and in the development phase we visualize the product for internal use, for use in web, marketing and PR related material. The Animations are often used in technical, or sales presentations of the mechanical solutions as well as the esthetical design.

Rendering Tools: 3D Studio Max • Catia V6 • Solid Works 2016 • KeyShot • Autodesk PDS

Documentation

Producing technical documentation in-house is crucial. We have the necessary understanding of the product and the component production to ensure the highest level of precision and quality. Our engineers cooperate with producers around the world to set up the item specifications and achieve the optimal tolerances to meet the required component price target.

Our technical writers and design-engineers are involved throughout the process to maintain a high level of consistency in all technical documentation. Userguides, assembly-instructions, brochures and service manuals are all developed in-house through the development phase and released in the industrialization phase.

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Documentation

Producing technical documentation in-house is crucial. We have the necessary understanding of the product and the component production to ensure the highest level of precision and quality. Our engineers cooperate with producers around the world to set up the item specifications and achieve the optimal tolerances to meet the required component price target.

Our technical writers and design-engineers are involved throughout the process to maintain a high level of consistency in all technical documentation. Userguides, assembly-instructions, brochures and service manuals are all developed in-house through the development phase and released in the industrialization phase.

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Industrialisation

To ensure that the product will be approved and manufactured according to the required quality level we cooperate with testing institutes and manufacturing sites around the world to ensure the product approval process. We set up test routines, do trials and part approvals, and we define golden samples and do the final quality agreements with the suppliers and manufacturing sites.

In parallel with the industrialization activities, our marketing, and brand management team finalize the commercial launch plan and media strategy, as well as all visual identity collateral for the product. Doing these steps in parallel removes the risk of late or incomplete commercial launches.

Our tools: Product testing facilities, Structured user testing, design for manufacturing (DFM), Item specifications, bill of material (BOM), commercial launch plan, Media strategy, Graphic toolbox, Pre-Production.

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Pre-production & Transfer process

Our process minds are set all the way to the production line of the product. We have the skills and facilities to do the first small-scale assembly of the prototypes and the pre-production of the units. We manage all file revisions, BOM, part numbering, assembly manuals and quality inspection documentation to prepare the product for mass production transfer. The transfer from developing the product to a «hand-over» to the manufacturing site is crucial for the quality. Fixture and jigs are all fine-tuned to meet the requirement of high or low volume production. By establishing the logistic parts of all components through the pre-production phase, the production line can easily be adapted to the next level of production volumes at the final manufacturing site.

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Verification & Validation testing

Verification test to verify that the product meets the customer or legal requirements we cooperate with testing institutes around the world from an early stage in the development process until industrialization phase. We build fixtures and do strength-tests, impact tests, vibration tests and cycle-tests in-house or at test institutes. Each product enters through a final round of rigorous functional and environmental tests to be certified.

Validation tests to validate that the product meets the requirements of the user and the market is done by randomly choose users to do testing which leads to the final product certification.

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Industrialisation

To ensure that the product will be approved and manufactured according to the required quality level we cooperate with testing institutes and manufacturing sites around the world to ensure the product approval process. We set up test routines, do trials and part approvals, and we define golden samples and do the final quality agreements with the suppliers and manufacturing sites.

In parallel with the industrialization activities, our marketing, and brand management team finalize the commercial launch plan and media strategy, as well as all visual identity collateral for the product. Doing these steps in parallel removes the risk of late or incomplete commercial launches.

Our tools: Product testing facilities, Structured user testing, design for manufacturing (DFM), Item specifications, bill of material (BOM), commercial launch plan, Media strategy, Graphic toolbox, Pre-Production.

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Pre-production & Transfer process

Our process minds are set all the way to the production line of the product. We have the skills and facilities to do the first small-scale assembly of the prototypes and the pre-production of the units. We manage all file revisions, BOM, part numbering, assembly manuals and quality inspection documentation to prepare the product for mass production transfer. The transfer from developing the product to a «hand-over» to the manufacturing site is crucial for the quality. Fixture and jigs are all fine-tuned to meet the requirement of high or low volume production. By establishing the logistic parts of all components through the pre-production phase, the production line can easily be adapted to the next level of production volumes at the final manufacturing site.

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Verification & Validation testing

Verification test to verify that the product meets the customer or legal requirements we cooperate with testing institutes around the world from an early stage in the development process until industrialization phase. We build fixtures and do strength-tests, impact tests, vibration tests and cycle-tests in-house or at test institutes. Each product enters through a final round of rigorous functional and environmental tests to be certified.

Validation tests to validate that the product meets the requirements of the user and the market is done by randomly choose users to do testing which leads to the final product certification.

Graphic Design

Our visual identity team creates seamless brand integration. Platform optimized and tailor-made solutions carefully crafted to highlight the essence and qualities of the product or company. The visual identity team benefits from the unique possibility to follow the product development process from start to launch. We believe that this makes for a better understanding of whats needed for the ultimate visual support, and to further promote the product in the best way possible.

Offerings include Product graphics, packaging, branding, logo design, web design, product animations, user guides, photography, cinematography, mobile application prototyping and more.

Visual Identity tools: Adobe CC, Keyshot, Invision, 3Ds MAX, Zbrush

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Graphic Design

Our visual identity team creates seamless brand integration. Platform optimized and tailor-made solutions carefully crafted to highlight the essence and qualities of the product or company. The visual identity team benefits from the unique possibility to follow the product development process from start to launch. We believe that this makes for a better understanding of whats needed for the ultimate visual support, and to further promote the product in the best way possible.

Offerings include Product graphics, packaging, branding, logo design, web design, product animations, user guides, photography, cinematography, mobile application prototyping and more.

Visual Identity tools: Adobe CC, Keyshot, Invision, 3Ds MAX, Zbrush

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