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Founders Lab

03 Process

From idea to small batch, step by step

Three phases, seven steps. Join at any phase: if you have a model, we skip design; if you have a prototype, we go straight to the batch.

Three phases

  1. Design

    We turn the idea into a dimensioned model that can actually be made.

    Step 01 · 02

  2. Prototype

    Physical samples, tests and revisions — until it’s right.

    Step 03 · 04 · 05

  3. Launch

    A small batch from the approved design, packaged and delivered.

    Step 06 · 07

Join at whichever phase fits.

07 Seven steps

Seven steps from first call to your door

  1. 01

    A · Design

    Call & brief

    We listen, then ask the awkward questions: who uses it, where, how many do you need? Together we separate must-haves from nice-to-haves.

    Result
    A clear brief and plan
    Time
    1–2 days
    Your part
    Tell us the idea, answer our questions.
  2. 02

    A · Design

    Design & 3D model

    Sketches, dimensions, a first 3D model. We look at it together — changing things before printing is always cheaper.

    Result
    Approved 3D model
    Time
    3–7 business days
    Your part
    Look at the model, comment.
  3. 03

    B · Prototype

    First prototype

    We print or cut the model. Now you have something to hold, weigh, test and even break.

    Result
    v1 — a physical first prototype
    Time
    2–5 business days
    Your part
    Hold it, try it, break it, take notes.
  4. 04

    B · Prototype

    Revisions

    Everything you notice once it’s in your hand goes into the next version. It usually takes a few rounds — that’s normal.

    Result
    v2, v3…
    Time
    2–4 business days per round
    Your part
    Say what you like and don’t — bluntly.
  5. 05

    B · Prototype

    Sign-off

    We agree the final version together: material, color, dimensions, finish, quantity. The batch is made to match it.

    Result
    Golden sample (reference)
    Time
    1 day
    Your part
    Approve the final sample.
  6. 06

    C · Launch

    Small batch

    We reproduce the approved design on the same settings and check every part for dimensions and finish.

    Result
    Small batch
    Time
    1–3 weeks
    Your part
    Wait — or come to the workshop and watch.
  7. 07

    C · Launch

    Packing & delivery

    Boxed, labeled, then handed over in Boston or shipped anywhere in the US and abroad.

    Result
    Ready-to-use product at your door
    Time
    1–5 days
    Your part
    Open the box.

Rules that don’t change

  1. R1 At the end of each step, we share in writing what was done.
  2. R2 If something won’t work well this way, we say so upfront.
  3. R3 If a change goes beyond the quote, we ask before doing it.
  4. R4 Two revision rounds are included in every quote.

Iteration

Prototypes take a few tries. They should.

Every version teaches you something. Here’s a desk phone stand in three versions and a small batch, with notes on what changed each time.

  1. v1 angle 70°
    56 mm · 70°

    First print

    The phone stands, but the charging cable doesn’t fit. The angle is a bit too steep.

  2. v2 + channel, angle 65°
    62 mm · 65°

    Cable channel

    Added a cable channel and dropped the angle to 65°. But the base is too light — it tips over when you tap the screen.

  3. v3 base + pad + logo
    86 mm · 65°

    Wider base

    Wider base with a recess for a non-slip pad underneath. Logo engraved on the front.

  4. batch same settings × qty

    Small batch

    The approved v3, reprinted on the same settings and fitted into its own box.

Example scenario — illustrative drawing. Two revision rounds are included in every quote.

Got an idea? Let’s start there.

Tell us about your project How it works