It all starts with the design…

The product design phase is one of the most critical steps in the overall product development process. Without a thoughtful and well-executed design, a molded fiberglass or thermoformed plastic part can quickly become expensive to manufacture, modify, and ship. On the other hand, a strategically designed part will transition smoothly from concept to production, with fewer costly adjustments and easier packaging, resulting in a more efficient and affordable build.

At Arrowhead, we’ve seen countless cases where a company is eager to move into production, but poor product design becomes the barrier. Designers unfamiliar with the thermoforming or fiberglass molding processes often create parts that are impractical or prohibitively expensive to produce. That’s why having a knowledgeable design partner—who understands not only form and function but also the production method—is essential for long-term success.

When a part is designed without considering manufacturing limitations, it often requires complete redesign. This leads to wasted time, money, and lost opportunities. Our team knows how to align design choices with real-world constraints, so your molded part is as efficient to make as it is functional in use. If your goal is to sell a product at a specific price point and volume, but the tooling costs don’t make financial sense, poor product design might be the issue. Effective design ensures your concept is scalable and cost-effective from the outset.

Arrowhead encourages all customers to engage with us early in the product design process. Whether you’re debating between fiberglass or plastic, we’re here to guide you. To better understand the differences between the two, check out this blog comparing molded fiberglass vs. thermoformed plastic. With over 40 years of experience in molded fiberglass and thermoformed plastic, we bring deep insight into the benefits, limitations, and cost-saving strategies of each process.

If you’re getting ready to enter the design phase of a molded part project, reach out to us first. Our goal is to make sure your product design meets your specifications, performs reliably, and is practical to manufacture. Let’s work together to ensure your concept becomes a successful reality.