The journey from ideation to creation, and then manufacturing can be difficult, but rewarding. Photo courtesy of OKGlobal

We live in a digital world. Music, movies, and even family photos have become primarily digital. Computer software offers us a range of comfort and efficiency and has become part of our daily routine. So, why would anyone want to build a career around physical product development?

Simple, almost every software product or next big thing relies on a well-executed physical product development project. Apps need a place to run, games need a console to be played, and pictures need a camera to be taken.

Physical product development means dreaming of something that does not yet exist and solves an existing problem. It means taking an intangible idea and making it into a physical item that people can see, touch, and use.

The journey from ideation to creation, and then manufacturing can be difficult, but rewarding. By understanding the process, you'll find that not only is your inspiration worth pursuing, but it may be one of the most fulfilling things you will ever do.

From inspiration to perspiration

Every product development project begins with a vision, the identification of a problem and a solution for that problem. That initial spark of inspiration is what drives the entire project.

Look for a problem that hasn't been solved and solve that problem, or try the reverse. Think of a product idea, and then work backwards to find the need. Regardless, one cannot be successful without the other.

Projects require this problem, or need, because it embodies the product's target market. A product idea without a well-defined need has no reason to exist, and if it did, it would be downright perplexing.

Once you identify your need and idea, start your research.

Test the validity of your idea. How much of a market exists for your problem-solving miracle? Send out surveys, look at various markets, conduct data analyses, and generally, do everything in your power to ensure that your product should be made.

Then, start making something.

From concept to reality

The design, prototype and manufacturing stages are what bring your inspiration closer to reality. Turning it into a concrete product means letting go, and that can be scary.

Initial concept designs can be done in a variety of different ways. Detailed sketches and blueprints could be drawn up, or CAD drawings can be created. This concept design can help you explain your idea to others, including partners and investors. What works even better, though, are prototypes.

A prototype is a preliminary model of your product that can help you determine the feasibility of different aspects of your design. You can make a functional prototype, which acts as a proof-of-concept for your idea, or you may create aesthetic prototypes that will test the look and feel of your product.

Once you nail down the ideal appearance and physicality of your product, you will need to combine the two disciplines as seamlessly as possible. This performance prototype will effectively demo your final product.

Finally, you can prepare your product for production. Designing for manufacturability (DFM) means ensuring that your product can be made efficiently and cost-effectively. DFM allows you to mistake-proof your product by choosing the best manufacturing materials and methods, while keeping in mind the appropriate regulations for your desired market.

From nothing into something

The product development process often changes. Trends like crowdsourcing and innovative fast-to-market solutions constantly upend the process and make it new again. Some automakers, for example, want to innovate the design process using existing customer data — similar to how companies like Microsoft and Apple create iterative versions of their software product development projects.

Getting your product to market can be tough, but certain approaches can ease the burden. Create a simpler product. Fail fast and fail cheap with lean development, meaning limit your risk to maximize your return. Also, never underestimate the importance of customer feedback and intellectual property protection throughout the process.

With that said, invest in yourself and your inspiration, and you will avoid that nagging what if-mentality that drives regret. Great reward always requires risk, but there are also ways to invest smarter. Use available resources and give your dream the best chance for success.

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Onega Ulanova is the founder of OKGlobal.

Making a product that is worth further investing in, one that customers will want to buy, requires several prototypes, sometimes tens of prototypes to prove the concept and perfect your idea. Photo courtesy of OKGlobal

Houston expert shares why prototyping is so important to startups

guest column

Rarely in life is anything perfect on the first attempt. Writers write drafts that are proofed and edited. Musicians practice over and over, and athletes train for years to perfect their skills before becoming pros. So, it only makes sense that a product developer would develop a prototype before manufacturing their products.

But why? Why can't a perfectly designed product go straight from CAD to production? In reality, making a product that is worth further investing in, one that customers will want to buy, requires several prototypes, sometimes tens of prototypes to prove the concept and perfect your idea. Success comes through practice, just like with the musicians and the athletes.

Defining "prototype"

The word prototype derives from the Greek word meaning, "primitive form." It's an early sample or model of a product built to test a concept or process. Understanding that a prototype, by definition, is an early form of your final product, know that there is often a compromise between your prototype and the final product design. Differences in materials, manufacturing processes and design may create a slightly different look and feel of your prototype.

A full design build is expensive, and it can be time-consuming, so before manufacturing, we create a prototype. This allows you to look for any flaws and problems, figure out solutions, then rebuild with the updates. The process may repeat multiple times. Rapid prototyping is often used for your initial prototype, allowing you to inexpensively build and test the parts of the design that are most likely to be flawed, solving issues on the front end, before you make the full product.

This necessary step is needed to progress with your product development and take you further toward the commercialization and marketing of your product.

Why prototype?

Prototyping allows you to learn about the product, the design, and the functionality. By doing repetitive prototyping, you eliminate the guesswork and base your decisions on actual data and facts. Don't ever guess. Just learn. Just prototype.

Market Testing
It allows you to put a product in front of your consumers, get their opinion, and make changes based on how the consumer uses the prototype.

Save Money
You get to save money on initial product testing, by letting consumers test the product the way they would use it in real life.

Make Improvements
Prototyping gives you the opportunity to make improvements before putting your product into the market. You can see where/if your idea is flawed and flush it out before you manufacture products that won't sell.

Sales Forecasting
This is a difficult enough task as it is, but when you have a new product, it's hard to predict how it will fare against other products in the market. By watching how consumers use the prototype, and by seeing it work against other products, you will begin to understand the sales cycle for that product, allowing you to start your forecasting.

Product designers cannot predict how a consumer will react to a new product, so they release several prototypes, and gather feedback, switching up the products until they find what works for the consumer. When the product went to manufacturing, and finally to market, it was almost guaranteed to be a success—an unintended use for prototyping, and yet one of its best uses.

Designers realize that what looks good on paper isn't always what the end-user is going to want. By getting an inexpensive prototype in front of consumers, designers have been able to get quick feedback, adjust the product, and create a winning product.

When it doubt, prototype it out

The beauty of prototyping is that each prototype interaction opens new opportunities to improve your product. In all reality, you will need more than one prototype to develop a truly valuable product. Product development can get bogged down in meetings, where the product is analyzed, and guesses are made as to "the best way," but by getting to the rapid prototype stage, you can skip some of that guesswork and replace it with real information from the customers.


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Onega Ulanova is the founder of OKGlobal.

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Houston researchers develop breakthrough device that could bypass spinal injuries

breakthrough research

Scientists at Houston Methodist have announced a significant leap forward for spinal cord injury recovery.

The researchers have developed a device that essentially bypasses spinal injuries, allowing signals from previously “lost” functions to reach the brain, a new study published in Nature Communications shows.

“Most current technologies try to improve whatever function remains after a spinal cord injury,” Dr. Damiano Barone, assistant professor of neurosurgery in the Department of Neurosurgery at Houston Methodist and co-lead on the study, said in a news release. “Our goal is different. Rather than fixing the injury itself, we want to bypass it completely and create an alternative route for signals to travel.”

The study involved a single ultrathin circumferential electrode array made to conform around the spinal cord without penetrating neural tissue, which was implanted into rodent and pig models with spinal injuries. The electrode array was able to interpret motor, sensory and autonomic signals around the injury. Think of it as a set of detours that restore road access to isolated towns after a disaster destroys the highway instead of just rebuilding the highway.

Over the course of three days, the arrays detected signals of intended movement from low-frequency spinal oscillations with more than 94 percent accuracy. This worked across species and was replicated in feasibility studies on human cadavers.

This research could serve as a new foundation for neuroprosthetic implants that could restore connectivity to the 2.5 million people worldwide suffering from spinal injuries that result in loss of ability. Future development could result in everything from restored organ function to mobility, according to Houston Methodist.

George Malliaras, the Prince Professor of Technology in the Department of Engineering at the University of Cambridge, who co-led the study, sees it as a fundamental restructuring of the science of spinal trauma.

“This could represent a paradigm change in how we think about spinal cord injuries,” Malliaras said. “Instead of starting from the idea that what is lost is gone forever, this approach asks whether we can restore function by carrying the signal around the injury.”

Further work involving laboratory models will need to be completed before launching human trials.

Grants from the National Institutes of Health, Houston Methodist Katz Investigator Award, Helaers Research Award and the Engineering and Physical Sciences Research Council helped support the study. Other collaborators on the study include Salim Hadwe, Ruben Serrano, George Psaltakis, Margaux Forner, Chaeyeon Lee, Sydney Swedick, Moleca Ghnnam, Tawfique Hasan and Alejandro Carnicer-Lombarte from the University of Cambridge; and Anton Banta and Xueer Zhang from Houston Methodist.

Abbott assembles expert team to help lure U.S. Space Academy to Texas

space race

State Rep. Greg Bonnen of Friendswood has been tapped to lead a new team that will promote Texas as the future home of the U.S. Space Academy.

Bonnen, a neurosurgeon, chairs Houston Physicians’ Hospital and the powerful Texas House Appropriations Committee. His House district is close to NASA’s Johnson Space Center.

Gov. Greg Abbott appointed the seven-member team. Last month, President Trump signed an executive order establishing the Presidential Commission on the U.S. Space Academy. Commission members, who held their first meeting this month, will recommend a permanent location for the academy.

Texas officials are pushing a site near Johnson Space Center to host the academy. Alabama, Colorado and Florida are among Texas’ competitors.

In a joint statement, U.S. Sen. Ted Cruz and U.S. Rep. Brian Babin, both of Texas, issued a statement backing the state’s bid for the academy. Cruz lives in Houston. Babbin lives in Woodville, about 55 miles south of Beaumont.

“America’s space program is built across the country, but Texas is where the pieces come together,” the lawmakers said. “We are ready to lead the next generation of space pioneers and look forward to showing why Texas is the right home for the U.S. Space Academy.”

The academy’s curriculum will include technical education, leadership development and public service components. Graduates will be set up for careers in the U.S. military, civil service, and aerospace sectors.

The Abbott-appointed team will work with the Texas Space Commission to prepare the state’s proposal for the academy.

In addition to Bonnen, team members with ties to Houston include:

  • Robert Ambrose, who grew up in Houston. He worked at Johnson Space Center before becoming associate director of the Texas A&M Space Institute.
  • Former NASA astronaut Nancy Curry-Gregg, director of the Texas A&M Space Institute. She earned a doctoral degree from the University of Houston and previously worked at Johnson Space Center.
  • Former NASA astronaut Jack Fischer, senior vice president of Houston-based Intuitive Machines. The company builds spacecraft, delivers payloads to the moon and launches satellites.

“Texas is the home of America’s human spaceflight program,” Abbott said in a release. “No state can match what Texas brings to this mission.”

“NASA’s Johnson Space Center, world-class universities, a premier commercial space industry, major military installations, and an unmatched aerospace workforce give Texas every asset the United States Space Academy requires,” the governor added.