Pilot Factory for manufacturability testing, pilot runs and validation
Producing small product series: from pilot to production
Do you want to validate a prototype, produce a zero series, or test your product's manufacturability? At the PEZY Pilot Factory in Groningen we connect design, engineering, toolmaking 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 rely on PEZY to turn their product into reality.
The foundation of a successful pilot run
Every pilot starts with a manufacturability analysis. With over thirty years of experience in polymer engineering and our own production facility in Groningen, we examine whether your design is suitable for the intended small batch. By assessing risks early, we reduce the chance of unsuitable moulds, disappointing trial runs and costly revisions.
Usage and loading
We examine usage scenarios and loads: impact, vibration, repeated motion and pressure. The part must not only function on the drawing board, but also withstand the conditions it is designed for.
Environment
Temperature fluctuations, moisture, chemicals, UV exposure and dust can all influence material and product behaviour. For that reason we assess these factors early and determine which practical tests are required.
Production volume
Twenty units for validation may call for a different approach than a few hundred for a pilot or several thousand for an initial series. Volume helps determine whether an aluminium mould, a hybrid solution or another production route is appropriate.
Fit and assembly
We look at how the part interfaces with electronics, seals, screws and other plastic components. By testing fit and assembly during the pilot phase, necessary changes can be incorporated before scaling up.
Sustainability
Recyclability and the use of recycled plastics, such as PCR, are part of the consideration. We assess whether the material meets the quality requirements, processing needs and intended service life.
Standards and validation from the initial analysis
Early on we map which requirements are relevant for your application and target market. This includes, among other things, CE marking, REACH and sector-specific rules. Not every product has 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 impact resistance and fire safety does the application demand? We translate those questions into design criteria and an appropriate test plan for the pilot.
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Materials and chemical requirements
We incorporate applicable substance and material requirements, including RoHS and REACH, into material selection. Even for PCR plastic we assess whether material data and performance suit the product and the necessary documentation.
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Sector-specific requirements
For medical applications, quality management requirements such as ISO 13485 may be relevant. For food contact we investigate the applicable EU or US FDA requirements. For industrial products we determine which sector-specific requirements and tests are necessary.
A small series of tests in the Plastics Lab
In the Pilot Factory the work does not stop at injection moulding. The test plan determines which properties we assess, which measurements are required and how the results are recorded. This makes clear what the pilot demonstrates and which questions remain open.
Strength and durability
Mechanical strength and fatigue tests help to assess behaviour under the agreed loads. The results give direction for improvements in design or material.
Dimensions and surface
We check dimensions and tolerances and assess surface quality. Among other things we look at sink marks, flow lines and the influence of the process.
Climate, chemistry and assembly
Climate tests, chemical resistance tests and assembly checks help to evaluate the series under conditions relevant to the intended use.
Golden Sample
An approved physical reference sample, together with the specifications, records which version has been agreed for further production. The Golden Sample supports handover and quality control.
From prototype to a 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 and then move to injection-moulded parts that represent the relevant properties of the final product. In our own workshop we make and modify aluminium moulds for pilot runs. For higher volumes or different requirements steel may be more suitable. We injection-mould, among others, on Demag machines.
A production route that suits your volumes
A pilot run or pre-production series can, for example, comprise 10 to 5,000 units. The appropriate quantity and mould choice depend on the product, the testing objective and the expected follow-up demand.
Why PEZY
Why produce small runs with PEZY?
The transition from prototype to market launch requires more than production capacity. PEZY connects engineering, toolmaking and production so findings can be shared quickly across disciplines. Early testing helps limit risks and align investments with the product’s stage. We focus on cost-efficiency for small runs, traceability and quality control. We also consider scaling and circularity. The result is a pilot that not only delivers parts but also the information you need to proceed responsibly.
3 locations
Design, engineering and production in close collaboration.
Pilot Factory
From first model to small series, in-house.
30+ years
Product innovation since 1995.
Great Place to Work
Recognised based on feedback from our employees.
Discuss your pilot run or small production batch
Do you want to produce small series, run a pilot or thoroughly validate a design? In a no-obligation intake we discuss your product, the desired volumes and the main risks. You will get a clear view of a suitable approach, without having to make a major production decision immediately.
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