Case Study: Accelerating Time to Market With Protobuilds
The Project
A startup sought a manufacturing partner capable of supporting rapid, iterative prototyping for its cutting-edge medical sensor assembly. It selected Intricon to provide design for manufacturing (DFM) guidance, radio frequency (RF) layout recommendations, and printed circuit board (PCB) expertise. Our customer-focused approach included build tracking, responsive communication, and 3-day turnaround to yield a high quality assembly while shaving months off the development timeline.
The Challenge
Developing a complex medical device required multiple design iterations in rapid succession. Traditional lead times are 2 to 4 weeks per spin, but that could have stretched the timeline into years. Frequent bill of materials (BOM) changes added a layer of complexity. Overall, our client needed a responsive partner who could quickly review designs, source materials, and build rapid prototypes within a shrinking timeline.
The Solution
Each build required design review, machining, tooling, quoting, documentation, and equipment programming, yet we developed new processes to deliver error-free protobuilds within just 3 days of receiving materials – a speed and quality few competitors could match. Our in-house engineers thoroughly reviewed each design, checking for design rules and process violations while recommending PCB layout improvements for RF and DFM. Once approved, we sourced materials (often overnight), built the prototypes, and sent them to our client for review – even hand-delivering when needed.
We also collaborated on a build tracker to monitor BOM updates, yields, and part numbers, with weekly status meetings for proactive communication. This was a true partnership where we operated as an extension of our client’s team. Through rapid prototyping, DFM consultation, and precision flex assembly, we helped our partner dramatically accelerate time-to-market for a highly complex medical device.
