Pilot Factory for manufacturability testing, pilot series and validation

Producing small production runs

Whether you want to validate a prototype, produce a pilot series (0 series / 10 to 5,000 units) or test your product for manufacturability, PEZY brings design, engineering, tooling and production together under one roof. Our own Pilot Factory in Groningen enables rapid iterations, reduces risk and ensures a smooth transition from prototype to series production, all with minimal costs and short lead times.

What is the foundation of a successful pilot production run?

The foundation for low risk small series production

Every project in our Pilot Factory starts with a thorough manufacturability analysis. We have seen firsthand what happens when this step is skipped: expensive tooling that does not perform as expected, pilot runs that fail to meet requirements and delays that businesses can rarely afford.

That is why we dive into it from day one. With more than thirty years of experience in plastics engineering and our own production facilities in Groningen, we carefully assess whether your concept is truly suitable for pilot production runs and small series manufacturing. Not just in theory, but in the way it will perform in the real world.

How the component is actually used

We start by taking a close look at the real world use cases and loads the product will face. How demanding are the actual operating conditions? Will it be exposed to impact, vibration, repeated movement or sustained pressure? We have seen many cases where a design looked perfectly fine on the drawing board, only to wear out or fail within weeks of real use. The best way to avoid that is to identify these risks early in the process.

How the environment affects the product

Next, we examine the environmental factors the product will be exposed to. Temperature fluctuations, moisture, chemicals, UV radiation and dust are all conditions that can have a significant impact in real world applications. From experience, we know these factors often play a much larger role than expected. That is why we assess them realistically from the very beginning.

How many units do you actually need to produce?

The expected production volume is a critical factor. Are you producing 20 units for validation, a few hundred for a pilot run or already moving towards several thousand units? That directly determines the most effective approach: aluminium tooling for speed and cost efficiency, a hybrid solution or another manufacturing strategy. By making the right choice early on, you avoid unexpected costs and unnecessary changes later in the process.

How it fits with the rest of the product

Next, we evaluate how the component integrates with the rest of the product. How does it connect to electronics, seals, fasteners or other plastic parts? In practice, assembly issues often arise at this stage. That is why we test fit, function and assembly during the pilot phase, ensuring that potential problems are identified early and avoiding major design changes later on.

Sustainability from the start

Finally, we incorporate sustainability from the very beginning. Not as an afterthought, but as a key consideration in the development process. Which materials can be effectively recycled? Can we use PCR plastics without compromising quality or manufacturability? We address these questions early on, ensuring that the final product is not only technically sound but also future proof.

Standards, validation & compliance: bringing products to market with confidence

In the Pilot Factory, we never leave standards and certifications to chance. We have seen too many companies discover late in the process that their product did not comply with CE, REACH or industry specific requirements. That leads to delays, additional costs and unnecessary frustration. That is why we incorporate compliance from the very first manufacturability analysis.

With our in house testing facilities in Groningen, we ensure that your pilot production run or small series is not only manufactured, but also properly validated and ready for the market.

Safety and protection in practice

We assess the required protection ratings from the start. Does the product need to meet IP65 or IP67 standards? What about impact resistance or fire safety requirements? Instead of making changes later in the process, we incorporate these requirements into the pilot tooling and validate them through realistic testing in our lab. This allows you to quickly determine whether the product performs as intended in its real world environment.

Environmental and chemical requirements

RoHS, REACH and other environmental and chemical requirements are now standard practice. We deliberately select materials that comply with these regulations and use PCR plastics wherever possible. Not because it looks good in marketing materials, but because we see that customers are increasingly held accountable for these choices and, in many cases, it is simply the smarter approach.

Industry specific certifications

Depending on your market, we assess the specific requirements that apply. For medical applications, we take standards such as ISO 13485 into account. For food contact products, we consider the relevant EU and FDA regulations, and for industrial applications we evaluate any additional sector specific requirements. We have worked on many projects where these considerations were incorporated during the pilot phase, making the transition to full scale production much smoother.

Comprehensive validation in our own laboratory

At the Pilot Factory, our work does not stop after injection moulding. We carry out extensive validation in our Plastics Lab, including:

We perform mechanical strength and fatigue testing, verify that dimensions remain within specified tolerances, closely inspect surface quality for issues such as sink marks and flow lines, and conduct climate testing, chemical resistance testing and assembly evaluations. Everything is aimed at ensuring that the products we manufacture continue to perform reliably in real world conditions.

Ultimately, we deliver a Golden Sample: a physical reference unit that serves as the benchmark for future production.

Prototyping, Tooling & Small Series Production: from concept to real product

Once we have assessed manufacturability and validated the key requirements, we move into production. At our Pilot Factory in Groningen, everything is under one roof: engineering, tooling, injection moulding machines and testing facilities. This streamlines the process and saves valuable time.

We have often seen companies get stuck between a promising prototype and actual production. That is why we specialise in bridging that gap. We typically start with industrial 3D printing for the initial evaluations, but quickly move to real injection moulded parts because they provide a much more accurate representation of the final product.

One of our biggest advantages is our in house tooling workshop. We manufacture aluminium moulds for pilot runs and small production volumes. They are quick to produce, cost effective and easy to modify if testing reveals improvements that need to be made. For higher volumes or more demanding requirements, we can also work with steel tooling. We mould parts on industrial grade Demag machines, so the components produced during the pilot phase are already very close to what you can expect in full scale production.

Whether you need 50 units for validation, 200 for a market launch or several thousand for an initial production batch, we can scale flexibly to meet your needs. And because everything is handled in house, we can respond quickly when adjustments are required. If the pilot phase is successful, we can also support the transition to full scale production, whether that takes place with us or with another manufacturing partner.

Manufacturability testing and DFM optimisation
Rapid prototypes through industrial 3D printing
Aluminium tooling for pilot runs and small series production
Steel tooling for higher volume production within the pilot phase
Injection moulding on Demag machines (small to medium sized production runs)
Comprehensive validation testing in our own Plastics Lab
Golden Sample as the reference standard for series production
Support with scaling up to full series production

Why choose the PEZY Pilot Factory?

We have helped many companies overcome the gap between a prototype and a successful market launch. What they often tell us is that having everything under one roof makes a huge difference. No hassle with multiple suppliers, no long lead times and no unexpected surprises halfway through the process.

Rapid iterations because engineering, tooling and production work closely together under one roof
Lower risk through early testing and validation
Improved cost efficiency for small series production and pilot runs
Full traceability and complete control over quality
A partner that helps you think ahead about scaling, circularity and long term sustainability.

Looking to produce small series, run a pilot production batch or thoroughly test your product for manufacturability?

At the PEZY Pilot Factory, we turn ideas into reality. We have helped many companies that were in exactly this stage: with a strong concept or prototype, but not yet ready for full scale production. That is why we like to start with a no obligation intake session. Together, we assess your product, target volumes and key risks, and provide clear advice on the best way forward. No commitments and no need to make major decisions right away.

Get in touch today!