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Our Process


Impactful and intuitive human centered design.

Detailed, collaborative, and experienced engineering.

Rapid prototyping and solution savvy production.

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  • Empathic Design

  • Brand Category Development & Strategy

  • User Interface Design

  • Brainstorming

  • Ideation

  • Form Studies

  • User Interface Design

  • Ergonomics

  • Virtual & Physical Modeling

  • Story Boarding

  • Photorealistic Renderings

  • Design Thinking

Design centers around human factors, identifying unmet opportunities, and ideation. By delivering dynamic designs, uniting form, function, and environmental considerations, Catalyst creates real products that connect with users while achieving strategic intent.

Catalyst delivers design thinking that works. Often, our clients ask us to simply redefine an existing product or brand. Other times, we are the springboard that sets the direction for new product and brand strategy. These are not just clever ideas, but thoughtful, real world solutions that make a difference in our clients' bottom line. Beginning with a period of discovery; we conduct user research, uncover unmet needs, collect inspiration, and capture imagery to develop dynamic and influential concepts and designs. Without compromising creative solutions or ideas, our industrial design team intuitively approaches design for manufacturing intent.

Unlike typical product development companies, our industrial designers work alongside engineers, tooling experts, and manufacturing specialists. This vertical integration of resources allows Catalyst to provide comprehensive brand and product development strategies.

Many design firms focus on aesthetics and let others worry about manufacturability and economic considerations. Catalyst focuses on creating real world product solutions while also delivering dynamic designs.

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  • Mechanical Engineering
  • Mold Flow Analysis
  • Structural Analysis (FEA)
  • Complex Surface Modeling
  • Enclosure Development
  • Development for Manufacturability

Engineering defines concepts ensuring structural, functional, and mechanical elements are resolved. Our Engineers consider real world aspects such as manufacturability, optimization, serviceability and user interface while still maintaining design integrity.

At Catalyst, we consider engineering to be an extension of the creative process. With over 150+ years of combined product development experience in industrial design and engineering, we complement our clients' core competencies. Additionally, this experience provides Catalyst with the ability to leverage unique ideas across diverse industries, ensuring innovative solutions.

The Catalyst engineering team considers the many ways a product may be used and identifies the intersection between optimum design and ideal manufacturing methods. Once a concept or direction is selected, our engineering team evolves concepts to maturity and resolves manufacturing details while enhancing the overall design intent.

Through a series of simulations and various rapid prototyping techniques, the Catalyst Product Development engineering team is able to anticipate potential obstacles and uncover valuable design enhancements. This product development approach and vertical integration of services reduces the length of time between critical stage gates, increasing our clients' bottom line.

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  • Prototyping:   Validating concepts through various prototyping materials, methods, and processes.
  • Tooling:   Building complex, custom, and quality injection mold tools through rapid tooling technologies.
  • Manufacturing:   Providing custom built solutions, low volume, and bridge production.

Realization is the validation of concepts through various prototyping methods, materials, and processes to better understand real world constraints and implications. Having extensive prototyping capabilities on-site allows our team to be responsive and integrate critical learnings more quickly.

True product development demands prototyping be an iterative process, discovering potential obstacles and implementing improvements, resulting in a fully matured concept. Catalyst realization is validating concepts through various prototyping methods, materials, and processes to better understand real world
constraints and implications.

At Catalyst, most prototyping methods can be completed internally. We guide our clients through the countless prototyping options to ensure proper selection aligns with the various project stage gates.

Realization can be as simple as sculpted clay model or as detailed as a production intent product. Regardless, we offer the latest technologies to validate form, fit, and function, as well as, structural integrity and manufacturability to ensure a seamless transition to production.


  • 3D Printing
  • FDM
  • Stereo-lithography
  • RTV / Urethane Castings
  • CNC Models


  • Rapid Tooling
  • Bridge Tooling
  • Production Tooling
  • Insert Tooling
  • QC10 Aluminum
  • P20 Steel
  • Edge, Diaphragm, Sub and Pin Gating
  • Direct and Hot Sprue Runner Systems


  • Computer Numerical Control Machines (CNC)
  • Electronic Discharge Machines (EDM)
  • Mills, Lathes, Carbon Electrode Production
  • Annealing Oven
  • Gravimetric Feeders
  • Multi-Channel Controllers
  • Injection Molding Presses: 85, 140, 165, 385, and 500 Ton