Our Process

Impactful and intuitive human centered design.
Detailed, collaborative, and experienced engineering.
Rapid prototyping and solution savvy production.



  Empathic Design
  Brand Category Development & Strategy
  User Interface Design
  Form Studies

  User Interface Design
  Virtual & Physical Modeling
  Story Boarding
  Photorealistic Renderings
  Design Thinking

Identifying Unmet Opportunities

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

Many design firms focus on aesthetics, letting others worry about manufacturability and economic considerations. Catalyst creates real world product solutions while also delivering dynamic design.

Beginning with a period of discovery, we conduct user research, uncover unmet needs, collect inspiration, and capture imagery. Without compromising creative solutions or insights, our industrial design team intuitively approaches design for manufacturing 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 and pretty pictures, but thoughtful, real world solutions that make a difference in our clients’ bottom line.



  Mechanical Engineering
  Mold Flow Analysis
  Structural Analysis (FEA)

  Complex Surface Modeling
  Enclosure Development
  Development for Manufacturability

Defining the Details of Design Success

At Catalyst, we consider engineering to be an extension of the creative process. Our engineers evaluate the many ways a product may be used, produced, assembled, serviced, and packaged. They strive to define the intersection between optimum design and ideal manufacturing methods. Our engineering team evolves concepts and resolves manufacturing details while enhancing the overall design intent.

With 200+ years of combined product development experience across many diverse industries and business segments, we complement our clients’ core competencies. This multi-industry experience allows Catalyst to leverage unique ideas across often unconnected industries, ensuring crossover thought and innovative solutions.

Our Engineers consider real world aspects such as manufacturability, optimization, serviceability and user interface while still maintaining design integrity. This product development approach and vertical integration of services reduces the development time to market, increasing our clients’ bottom line.




Validating concepts through various prototyping materials, methods, and processes.

  3D Printing
  RTV / Urethane Castings
  CNC Models


Building complex, custom, and quality injection mold tools through rapid tooling technologies.

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


Providing custom built solutions, low volume, and bridge production.

  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

Realizing Complete Product Development

Design realization is at the core of our capabilities. It is the validation of concepts through various rapid prototyping methods, materials, and processes to better understand real world constraints and implications. Catalyst offers extensive on-site prototyping and manufacturing capabilities that allows our team to be responsive and integrate critical learnings more quickly.

To stop after the concept is rendered on a computer is not product development–that’s art. It may look nice, but it will not create revenues, build brands, or gather market share. We have complete in-house, prototyping, tooling, manufacturing, and assembly capabilities. We do not outsource design realization services as many firms do. Your intellectual property is too valuable.

At Catalyst, 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 models or as detailed as a production intent product. Regardless, we offer the latest technologies to validate form, fit, function, structural integrity and manufacturability to ensure a seamless transition to production.

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