Contract Mfg & Prototyping

Contract Mfg & Prototyping

In the demanding world of quick turnaround schedules and the need for reliable suppliers, Optimal Design is focused on giving our clients the best possible options, from single-piece prototype parts to complex, high volume production runs.

Optimal Design’s onsite manufacturing facilities are designed to accommodate engineering builds and long-term production. Our integrated testing, quality, and procurement teams ensure each product is built to your exacting standards. Coupled with our global supplier connections, our clients receive the benefit of one point of contact and the advantage of preferential pricing.

Optimal Design has expanded the scope of making quality parts and adapted it using the new features and capabilities of the latest technology. As the Industrial Internet of Things impacts business, incorporating additive manufacturing and 3d printing, we can help your business stay competitive.

We can give you fast, accurate representations of your concept with a variety of methods to suit your timing and budget – sometimes overnight – ranging from simple ergonomic studies to fully finished showroom-quality pieces.

Why Optimal

  • Speed to market
  • Flexibility to run low-to-medium volume production
  • In-house engineering & NPI Teams
  • US-based operation offering premier intellectual property security
  • High quality, complex assembly of tech-based products
  • Strategically located in mid west with local trusted suppliers

Manufacturing & Operations

Our manufacturing operations are led by experienced staff who understand how to rapidly scale products. From complex IoT smart city devices to ultra rugged electro-mechanical consumer devices, we’ve been there and built that.

  • Supply chain/vendor management
  • Logistics planning
  • Comprehensive sourcing
  • Final packaging and labels
  • Production cell planning
  • Cost optimization & BOM management
  • Prototype production
  • Low-mid volume box build capabilities
  • Complete product testing
  • Thermal & RF test chambers
  • Flexible manufacturing space for rapid scaling
  • System burn-in
  • Certified repair stations
  • Managed production systems

Onsite NPI Engineering Team

Our world-class New Product Introduction (NPI) engineering team has commercialized hundreds of products throughout consumer, industrial, and medical industries. Our NPI team sets a firm foundation for each customer-specific manufacturing solution and engages closely throughout the process to ensure products achieve required functionality, quality, and standards. NPI activities include:

  • DFM/DFA analysis
  • Test & quality plan development/implementation
  • Manufacturing line bring up & staff training
  • First article inspection
  • Pilot build troubleshooting


Headquartered in suburban Chicago, the Optimal Design Manufacturing facility and co-located with the engineering hub span +50,000 sq ft. Onsite test labs for electrical, mechanical, and RF/antenna testing accelerate speed to market and de-risk product launches.

Rapid Prototyping

Product development is fast moving and requires capabilities that accelerate the development process. In order to compress timelines, Optimal Design leverages its own prototyping facility to expedite design iterations and time to market.

  • 3D Acrylic Printing
  • SLA/SLS Rapid Prototyping
  • Urethane Castings
  • CNC Machining

Prototype Tooling

Our teams have sourced and qualified hundreds of prototype and production tools both domestically and offshore for our clients. We have spent the past two decades identifying, qualifying, and working with our global tooling partners and are able to provide a single point of contact and preferential pricing.

  • Injection Molds
  • Die Casting
  • Progressive Dies

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