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Have you come up with a "better mouse trap?" Bayden Engineering offers full design through manufacturing services. Regardless of the complexity of your concept, we have everything required to bring that idea to fruition. Here is an example of a "typical" design to manufacturing cycle on a consumer product that was designed and marketed by Bayden Engineering.

Phase 1: Conceptualizing

For our example we will design a new bicycle seat.

Define criteria for the product or item


  • Large bike seat

  • Safe

  • Sturdy

  • Comfortable

  • Steel reinforced Plastic

  • Fit on most existing bikes

  • Easy to install

  • Reasonably priced


A Bayden Engineering consultant helping conceptualize a new product design

Phase 2: Rough Layout

Using 3D CAD, create a rough conceptual model Based on the design criteria, we have created a large seat area that will be reinforced with a steal rod. The steal rod will also be used for mounting the seat.

3D CAD solid model of a preliminay Bike Seat design

Phase 3: Analysis
Use the tools required to analyze the design for failure issues and areas. In this image, Finite Element Analysis (FEA) is used to locate areas of excessive stress on the design.

Phase 4: Refine
Alter the design based on changed criteria or analysis results. This often an iterative process where the design is sent back through the analysis phase until an optimized design is created. Material selection can greatly alter results.

Finite Element Analysis (FEA) of a bike seat design

Phase 5: Define Manufacturing Documentation
Manufacturing can create there CAM data directly from the refined 3D CAD solid model or from 2D drawings.

2D drawing made from a 3D solid Model of a bike seat design
3D solid Model of a bike seat design

Phase 6: Define Packaging Concepts
Using 3D CAD, define what type of packaging you want. This is an important and often over-looked process. Packaging can take up space. And dependent upon where your products will be manufacture or shipped, the volume of the package can dictate the shipping costs.

3D solid Model of a packaging concept for a bike seat design

Phase 7: Create Packaging Engineering Data
Create packaging production data. In this case, the information for the paper cutting die. Notice the punched holes (on the left) to accommodate how the product will be displayed in the marketplace. In this case, they will be hung on hooks. Just another example of the amount of thinking that goes into a new product.

2D CAD drawing for a cutting die used on a bike seat package

Phase 8: Create Packaging artwork
Artwork can mean a myriad of things which include:

  • Assembly instructions

  • Installation instructions

  • User warnings

  • Replacement Parts catalog

Using the CAD file, the packaging can be evaluated and visualized.

3D CAD solid model of fianlized bike seat with packaging
An image shwing alternate packaging artwork of install instructions

The Final Product

Picture of completed bike seat design
Completed bike seat installed onto a bicycle
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