10-stage proven framework
From raw idea to development-ready in 10 stages
Our framework was built from 280+* real product developments. Stages 1–6 are delivered by AI in the free sprint. Stages 7–10 are guided by our engineering team when you’re ready.
Stages 1–6: Free Sprint
AI-guided, at your pace, around 2 hours
Stages 7–10: Expert-Led
Human engineering, manufacturing, production
The complete product development journey
Click any stage to see what happens, what the AI produces, and what you’ll have when it’s done.
Viability Sprint — AI-Delivered (Free)
Guided Next Steps (Expert)
1
Idea Capture
2
Discovery
3
Innovate
4
Evaluate
5
Define
6
Dev-Ready
7
Prototype
8
Test
9
Tooling
10
Manufacture
Stage 1 of 10
Idea Capture
You describe your product idea in plain language — what it does, who it’s for, and the problem it solves. The AI guides you through structured questions to extract the core concept, even if you only have a rough sketch in your head. No technical knowledge needed.
AI-Delivered
What you’ll have after this stage
Product concept statement
Target user definition
Core problem articulation
Initial use-case scenarios
Success criteria framed
Stage 2 of 10
Discovery
The AI maps your competitive landscape, identifies existing solutions, and highlights gaps your product could fill. You’ll understand market size indicators, pricing benchmarks, and where comparable products succeed or fall short.
AI-Delivered
What you’ll have after this stage
Competitor analysis summary
Market gap identification
Pricing benchmark data
User needs mapping
Differentiation opportunities
Stage 3 of 10
Innovate
Feature prioritisation using the MoSCoW method — what must your product do vs. what would be nice to have? The AI helps you identify your key differentiators and think through IP considerations before spending money.
AI-Delivered
What you’ll have after this stage
MoSCoW-prioritised feature list
Differentiation strategy
IP and patent considerations
Innovation opportunity map
Learn more: MoSCoW Prioritisation | Protecting Your Product Idea
Stage 4 of 10
Evaluate
Hard questions time. The AI assesses technical feasibility, identifies manufacturing constraints, flags regulatory requirements, and scores commercial viability. This is where non-viable ideas get caught — saving you thousands.
AI-Delivered
What you’ll have after this stage
Technical feasibility assessment
Manufacturing constraint analysis
Regulatory / compliance flags
Commercial viability score
Risk register with severity ratings
Learn more: Feasibility Assessment Guide | Understanding Product Risk
Stage 5 of 10
Define
Everything comes together. The AI generates a structured product specification, development timeline with stage-by-stage durations, and indicative cost estimates — each confidence-rated so you know exactly what’s validated vs. estimated.
AI-Delivered
What you’ll have after this stage
Structured product specification
Development timeline (staged)
Confidence-rated cost estimates
Resource requirements outline
Bill of materials (initial)
Stage 6 of 10
Development-Ready
Your complete Viability Brief — a single document bringing together everything from stages 1–5 into a format you can share with investors, co-founders, or engineering teams. Includes prioritised next steps and a recommended path forward.
AI-Delivered
What you’ll have after this stage
Complete Product Viability Brief
Investor-ready summary document
Prioritised next steps
Go / No-Go recommendation
Expert Review recommendation
Stage 7 of 10
Prototyping
Turn your validated specification into physical form. This could range from 3D-printed proof-of-concept models to functional prototypes depending on complexity. Our engineering team at Cast Iron CAD manages the entire process.
Expert-Led Cast Iron CAD
What you’ll have after this stage
3D CAD model
Physical prototype (proof-of-concept or functional)
Design-for-manufacture feedback
Refined cost estimates
Learn more: Prototyping Methods Explained | 3D Printing vs CNC Machining
Stage 8 of 10
Testing & Validation
Verify your product works as intended. Depending on your product category, this includes functional testing, user testing, regulatory compliance testing, and environmental assessments. Results feed directly back into the specification.
Expert-Led Cast Iron CAD
What you’ll have after this stage
Test reports and results
Compliance / certification documentation
User feedback integration
Specification refinements
Stage 9 of 10
Tooling & Pre-Production
Prepare for manufacturing at scale. This covers production tooling (moulds, jigs, fixtures), supplier selection, quality control setup, and pre-production sample approval. The critical bridge between prototype and production.
Expert-Led Cast Iron CAD
What you’ll have after this stage
Production tooling (moulds, jigs, fixtures)
Approved supplier chain
Quality control plan
Pre-production samples signed off
Learn more: Understanding Tooling Costs | Choosing a Manufacturing Partner
Stage 10 of 10
Manufacturing & Delivery
Full production run, quality assurance, packaging, and delivery logistics. Whether it’s a batch of 100 or a run of 100,000, we manage the entire production process from order to delivery.
Expert-Led Cast Iron CAD
What you’ll have after this stage
Finished product — manufactured and QC’d
Packaging and labelling
Delivery logistics arranged
Ongoing production support
Learn more: Manufacturing Methods Compared | Quality Control in Production
Transparent about what AI can and can’t do
We don’t pretend AI replaces an engineer. We use it where it’s strongest, and bring in human expertise where it matters most.
Capability
AI Sprint (Free)
Expert Review (£49)
Market & competitor research
Feature prioritisation (MoSCoW)
Technical feasibility assessment
Indicative
Regulatory / compliance flagging
Flags only
Cost estimates
Ranges
Manufacturing method recommendation
General
Supplier-validated pricing
—
Go / No-Go recommendation
AI-generated
Risk items AI might miss
—
Personalised next-step action plan
Template
The sprint gives you an 80% picture for free. The Expert Review closes the last 20% — the part that can save you thousands. If you don’t get a clear next step from the review, we refund the £49.
Built from what actually works
This isn’t academic theory or a generic checklist. Every stage in the framework was distilled from delivering real products to real markets — from consumer electronics to garden structures to medical devices.
The 10-stage process captures the activities that consistently determine whether a product succeeds or fails. We identified 98 key activities across the full lifecycle, then built an AI system that can guide you through the first six stages as effectively as sitting in a room with an engineer.
280+*
Products delivered
98
Key activities mapped
40+
Years experience
How the framework was built
Real project delivery
280+* products across every category and manufacturing method
Pattern extraction
98 activities that consistently determine success or failure
AI adaptation
Stages 1–6 rebuilt as guided conversations anyone can follow
Continuous refinement
Every sprint improves the framework — real feedback, real outcomes
See it in action
The best way to understand the framework is to use it. Start your free Viability Sprint and experience stages 1–6 firsthand.
Free — no card required
Under 2 hours
AI-guided, at your pace
*Based on product concepts assessed across Cast Iron CAD and Innovate Engineer projects since 2018.