Why Hands-On Engineering Experience Matters in Product Design
Creativity and innovation are at the core of product design, but no matter how sleek a product looks on paper, it must function in the real world. This is where practical, hands-on engineering experience becomes invaluable. Designing a product isn’t just about making it look good—it’s about making sure it works and can be efficiently manufactured, assembled, and used without issues.
In product design, engineers ensure concepts remain grounded in reality, balancing creativity with functionality, manufacturability, and cost-effectiveness. However, there’s a deeper layer to this process: the ability to predict and avoid engineering headaches before they arise.
The Ability to Evaluate Concepts Early
Having spent years in metal fabrication and hands-on engineering, or director Martyn has developed an intuitive sense for how things will actually work—or possibly more important how they might NOT work! This experience gives him the ability to evaluate whether a concept is worth pursuing or if it’s likely to become a costly, time-consuming problem. While no one can predict issues with 100% accuracy, having a strong “radar” for design paths that could lead to major challenges allows our team to avoid unnecessary complications from the outset.
For example, some design ideas may seem brilliant in theory but are impractical due to material limitations, complex assembly requirements, or unrealistic tolerances. Martyn’s hands-on background allows him and the team to spot these red flags early, saving time, money, and frustration later down the track.
Bridging the Gap Between Design and Reality
In product development, designers focus on aesthetics, user experience, and innovation, while engineers ensure those ideas are feasible to manufacture and function correctly. However, without practical engineering experience, it’s easy for designs to become disconnected from manufacturing realities. This is where a strong understanding of real-world engineering principles makes a significant impact.
With years of direct fabrication and mechanical engineering experience, he can recognise where a design may run into manufacturing bottlenecks, excessive production costs, or durability concerns. This allows his team to make informed design decisions before investing heavily in prototyping or production.
Faster, More Effective Prototyping
Prototyping is a critical phase in product development, but it can also be a costly one—especially if designs aren’t well thought out from the beginning. Engineers with hands-on experience understand how to build and iterate quickly, reducing wasted time and resources. They understand hat you should test the most risky or concerning parts of the design first if at all possible to reduce or eliminate those risks or possibly change direction if the risks prove too high or problems are too costly and time consuming to solve.
For instance, when we develop prototypes at our company, we don’t just create a model to look at—we ensure it’s as close to real-world conditions as possible. If an issue arises, we can immediately diagnose and modify the design based on real mechanical knowledge rather than relying solely on trial and error or theoretical knowledge only. This approach makes the prototyping process much more efficient and cost-effective as well as faster.
Avoiding Manufacturing Pitfalls
A product that works in theory but can’t be manufactured efficiently is a failed product. Martyn’s experience in metal fabrication, hands-on mechanical engineering as well as mechanical workshop experience gleaned from 30+ years of riding and fixing motorcycles provides insights into manufacturing techniques, material constraints, and production feasibility. Engineers who understand these real-world constraints can design for manufacturability from the outset, reducing production costs and preventing last-minute redesigns.
For example, working with manufacturers directly means we can anticipate issues related to tooling, part tolerances, and assembly line setups, ensuring smoother production runs. This hands-on knowledge not only improves efficiency but also enhances product longevity and sustainability.
Final Thoughts
In product design, hands-on engineering experience is more than just a bonus—it’s a necessity. It enables better concept evaluation, faster and more effective prototyping, and designs that seamlessly transition into manufacturing without costly redesigns.
At Design+Product we combine expert design with real-world engineering know-how, helping clients develop products that aren’t just innovative but practical, scalable, reliable and built for success. Whether you need a turn-key design department to design the whole product or just an experienced partner to produce awesome design concepts, we’re here to help.
Ready to bring your product idea to life? Contact us today and let’s create something amazing!
