Pilot Factory for manufacturability testing, pilot runs and validation
Small-batch production: from pilot to production
Do you want to validate a prototype, produce a pre-production run or test your product’s manufacturability? At the PEZY Pilot Factory in Groningen, we bring together design, engineering, mould making and production. From a few dozen to several thousand units, we tailor the run to what you want to learn, the technical requirements and the next step towards production.
These companies trust PEZY to turn their product ideas into reality.
The foundation of a successful pilot run
Every pilot starts with a manufacturability analysis. Drawing on more than thirty years of experience in plastics engineering and our own production facilities in Groningen, we investigate whether your design is suitable for the intended small batch. By assessing risks early, we reduce the likelihood of unsuitable moulds, disappointing pilot runs and costly modifications.
Use and loads
We investigate usage scenarios and loads, including impact, vibration, repeated movements and pressure. The component must not only work on the drawing board, but also withstand the conditions for which it is designed.
Environment
Temperature fluctuations, moisture, chemicals, UV radiation and dust can affect how the material and product perform. We therefore assess these factors early on and determine which real-world tests are needed.
Production volume
Twenty units for validation may require a different approach than a few hundred for a pilot or several thousand for an initial production run. The volume helps determine whether an aluminium mould, a hybrid solution or another production route is appropriate.
Fit and assembly
We examine how the component interfaces with electronics, seals, screws and other plastic parts. By testing fit and assembly during the pilot phase, any necessary changes can be incorporated before scaling up.
Sustainability
Recyclability and the use of recycled plastics, such as PCR, are part of the assessment. We investigate whether the material meets the quality requirements and is suitable for the processing method and intended service life.
Standards and validation from the initial analysis
We identify at an early stage which requirements are relevant to your application and target market. This includes CE marking, REACH and industry-specific requirements. Not every product is subject to the same obligations, and a pilot run is not automatically certified or market-ready.
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Safety and protection
Is protection against dust and water required, for example IP65 or IP67? What levels of impact resistance and fire safety does the application require? We translate these questions into design criteria and an appropriate test plan for the pilot.
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Materials and chemical requirements
We incorporate applicable requirements for substances and materials, including RoHS and REACH, into the material selection process. For PCR plastics, too, we assess whether the material data and performance are suitable for the product and the required supporting evidence.
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Industry-specific requirements
For medical applications, quality management requirements such as ISO 13485 may be relevant. For food-contact applications, we investigate the applicable EU or US FDA requirements. For industrial products, we determine which industry-specific requirements and tests are needed.
Testing a small production run in the Plastics Lab
At the Pilot Factory, the work does not end with injection moulding. The test plan determines which properties we assess, which measurements are needed and how the results are recorded. This clarifies what the pilot demonstrates and which questions remain open.
Strength and service life
Mechanical strength and fatigue tests help assess performance under the agreed loads. The results guide improvements to the construction or material.
Dimensions and surface finish
We check dimensions and tolerances and assess surface quality. This includes examining sink marks, flow lines and the impact of the process.
Climate, chemicals and assembly
Climate tests, chemical-resistance tests and assembly checks help assess the production run under conditions relevant to its intended use.
Golden Sample
Together with the specifications, an approved physical reference sample defines the agreed version for further production. The Golden Sample supports the handover and quality control.
From prototype to small production run
Engineering, mould making, injection-moulding machines and the test lab work closely together in Groningen. Where appropriate, we start with industrial 3D printing for initial checks, before moving on to injection-moulded parts that represent relevant properties of the final product. In our own workshop, we produce and modify aluminium moulds for pilots. Steel may be more suitable for higher volumes or different requirements. Our injection-moulding equipment includes Demag machines.
A production route tailored to your volumes
A pilot or pre-production run may, for example, comprise 10 to 5,000 units. The appropriate quantity and choice of mould depend on the product, the test objective and expected follow-up demand.
Why PEZY
Why produce small batches with PEZY?
The transition from prototype to market launch requires more than production capacity. PEZY connects engineering, mould making and production, allowing findings to be shared quickly across disciplines. Early testing helps mitigate risks and align investments with the product’s stage of development. We consider cost efficiency for small production runs, traceability and quality control. Scaling and circularity are also taken into account. The result is a pilot that delivers not only parts, but also the information you need to move forward responsibly.
3 locations
Design, engineering and production working closely together.
Pilot Factory
From initial model to small production run, all in-house.
30+ years
Product innovation since 1995.
Great Place to Work
Recognised based on feedback from our employees.
Discuss your pilot or small production run
Do you want to produce small batches, run a pilot or thoroughly test a design? During a no-obligation initial consultation, we discuss your product, the desired volumes and the main risks. You will gain a clear understanding of a suitable approach without having to make a major production decision straight away.
Contact
Schedule a meeting
Choose a time that suits you. We will discuss your pilot run and a logical next step.