Product Development — Concept to Production, Sydney Made
Forge Labs combines industrial design, mechanical engineering and in-house manufacturing into one accountable product development programme. From back-of-napkin sketch to manufacturing-ready CAD and pilot production runs — all under one Sydney-based engineering team.
Typical projects start from $500+ · Engineering & business enquiries welcome · Upload CAD, STEP & STL files for review
Manufactured in
Sydney, Australia · Quality-checked on every job
Why Forge Labs
Why teams trust Forge Labs with their product
An engineering-led, manufacturing-aware product development partner that lives a few suburbs away.
Concept to Production, One Roof
Industrial design, mechanical engineering, prototyping and manufacturing under one Sydney-based programme manager.
Engineer-Led, Designer-Polished
Mechanical and electromechanical engineering combined with industrial design sensibility — products that work and sell.
Manufacturing-Aware Design
Every design decision is made with the manufacturing process in mind — no "un-buildable" CAD handed off to manufacturers.
Rapid Iteration Cycles
Prototype, test, learn and revise in 1–2 week cycles using our in-house additive and CNC fleet.
IP & NDA First
Mutual NDAs before any files change hands. IP is yours throughout the engagement and after.
Our Workflow
How a product development programme runs
Discovery & brief
We dig into the problem, the user, the market and the cost target. Output is a written design brief and a milestone plan.
Concept & CAD
Sketches, concepts and CAD developed iteratively with weekly review. You see and approve direction before any tooling decisions.
Prototype & test
Functional prototypes built in our workshops, user-tested or lab-tested, then revised. Typically 2–4 iteration cycles.
Production handoff
Tooling specification, BOM, drawing pack and pilot manufacturing run handed off — or stay with us into low-volume production.
What we deliver
Engineers who actually build the product they design
Industrial design · Mechanical engineering · DFM · Prototyping · Pilot production
A surprising number of product development consultancies hand off CAD to a manufacturer they've never met. Forge Labs operates the manufacturing too — which means every design decision is made with the printer, the CNC, the injection mould and the assembly line in mind from day one. Your prototypes are built by the same workshop that will eventually run pilot production, by engineers who understand exactly what's manufacturable and what isn't.
- Industrial design and mechanical engineering under one team
- Iterative prototyping in our own additive and CNC workshops
- User testing, ergonomic studies and design verification baked into the process
- DFM and tooling specification handed off as a complete pack
- Pilot production runs on Forge Labs equipment — or hand-off to your manufacturer
- Mutual NDA from day one; full IP transfer with every milestone
Industries we serve
Products we've helped bring to market
Consumer goods, medical devices, scientific instruments, defence kit and industrial equipment — designed and prototyped in Sydney.
Consumer Products
Direct-to-consumer goods, sporting equipment, kitchenware and lifestyle products from concept to retail launch.
Medical Devices
Class I and Class IIa device development with regulatory-ready documentation packs (regulatory submission is your responsibility).
Scientific Instruments
Lab equipment, research rigs, automated test cells and custom scientific tooling for universities and biotech.
Cleantech & Sustainability
Energy, water and waste-stream products designed for the next decade of decarbonised industry.
Defence & Dual-Use
Confidential product development for Australian defence primes, SMEs and dual-use commercial spinouts.
Industrial Equipment
OEM-grade machinery, materials handling, fluid systems and ruggedised industrial product development.
Showcase
Recent product development work
Functional development prototype — multiple iterations on a single concept.
SLA appearance model used for stakeholder review and user testing.
Pilot injection-moulded production run for a Sydney consumer brand.
FAQ
Frequently asked questions
Explore more
Related 3D printing services
Ready to start your project?
Upload your file or send a quick brief — most quotes come back within 4 working hours, with parts dispatched Australia-wide from our Sydney workshops.