Do you want to develop a charging product? In just seven steps, we turn your idea into a final design.

23 May 2019

The development of any charging product starts with an idea. Of course, there are myriad ways to bring an idea to life. In just seven steps, our engineers help you create the perfect product design. One that is exactly what you want it to be: beautiful, functional, durable – and realisable, of course, although that’s a given when you work together with us.

1. Defining the idea

During this step, we sit down with you to find out exactly what your demands, wishes and expectations are. Together with you, we go through an extensive checklist. What must the charging product be able to charge? Who will use it and where? What is the product’s maximum price? We will also go over the legal requirements for charging devices. For example, all chargers must have a CE certification. In North America, they use UL/CSA standards. Our experts advise you on the most suitable plastic material to use.

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2. Analysing functionalities

During step two, we will explore the primary functionalities of your charging product in more detail. We will select the most suitable charging technology, such as Qi technology, radio frequency or infrared. We will identify any problems that may arise and figure out how to solve them. For electric chargers that are primarily used in damp environments, it is essential that they are fully waterproof. Think of e.g. a charger for a shaver or an electric toothbrush. For wireless chargers, it is important that the device “connects” properly to the charger, instead of simply sliding off and ending up outside the charging zone. It may also be necessary for consumers to be able to tell whether their device is being charged by looking at the charging station or the product. That is another factor to include in the product design.

During this phase, our designers will also conduct research into similar products that are already available on the market, for example by visiting stores and trade fairs and searching online.

3. Selecting solutions

During this step, we choose the best solutions for the issues that we analysed in step two. For example, we can make a charger waterproof by using a special injection-moulding technique called 2K injection moulding. Keeping a device inside a wireless charger’s charging zone can be realised by adding a “slot” to the charging station for the device to fit into. To show the device’s charging status, we can include an LED light and a lens with different colours. Users can tell by the colour of the light whether the product is charging.

During step three, we will also create the first rough sketches and 3D prototypes of the various product components. We conduct an FMEA – or failure mode effects analysis – for the preliminary solutions we have selected. This analysis is used to identify potential design errors, so we can quickly resolve and/or avoid them.

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4. Sketches and 3D prototypes

During step four, ideas, drawings and our chosen solutions come together. We create a prototype of the entire product – or products, if we want to compare different solutions to find the best one. Of course, you as the customer are closely involved in this process. You can get a first look at what your product could eventually look like. Together, we will assess the sketches and prototypes and decide how to implement the charging technology we selected. During this phase, we also go through the DFM process, where we analyse the manufacturability of the product in the mould. As Rompa Group is involved as an ODM partner in this case, the DFM process can proceed much more efficiently than if we only acted as a producer. After all, an engineer has been considering the manufacturability of your product since the design phase, which shortens the lead time of the development process and saves costs.

5. Developing the selected option

Once the big picture is complete, we will start working on the fine details of your product’s external and internal design. We evaluate the prototype and make any necessary adjustments. As a result of our close collaboration during the first four steps, we have developed a solid partnership. We know your wishes and demands and you know what to expect from us. That ensures the process proceeds as smoothly as possible.

6. Semi-final design

The design is almost finished now. We know what the product will look like and how it works on the inside. Now it is time for the finishing touches: things like texture, printing a logo, and labelling.

7. Final design

Once the design is to your complete satisfaction, there will be a “design freeze.” Based on the chosen design, we will create prototypes that you can use for testing. If everything is in order, you can approve the start of the manufacturing process for the moulds.

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Contact our charging specialist

Are you looking for an ODM partner for your charging product? Our charging specialist Peter Dielissen would love to discuss the possibilities with you. You can contact him via +31 (0)13 204 09 85 or email: peter.dielissen@rompa.nl.

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