Source: MEP National Network

The entrepreneurial inventor wants to make something that doesn’t exist and lives in a world of trials, pivots and improvisation. Manufacturing is at the opposite end of the operational spectrum, relying on highly engineered and repeatable processes.

Too often, entrepreneurs of all types lack the knowledge of manufacturing and contacts required to take the next step to produce their products at scale. It’s critical for entrepreneurs to learn about manufacturing at scale.

This is why NextCorps, which is part of the MEP National Network, created the Manufacturing Accelerator (MA) in 2018 to bridge the gaps that often exist between hardware technology inventors/entrepreneurs and the contract manufacturers they need to mass produce their products. NextCorps saw the opportunity to help increase the rate of new production commercialization, job creation and economic growth. But achieving results at the intersection of innovators and manufacturers requires building and nurturing relationships.

The MA began with pilot programs in Rochester, New York, and then in Pittsburgh, Pennsylvania, with InnovationWorks and Catalyst Connection, which are also part of the MEP National Network. MA has also become part of the Luminate Accelerator for Optics Photonics and Imaging startups (which is run by NextCorps), and the ChargeUp Accelerator for Energy Storage startups run by New Energy New York and Binghamton University. MA has helped teams develop hardware for climate tech, industrial products and consumer products.

Startups often struggle with the design for manufacturing gap

The gap between developing an innovative product and successful commercialization is known as the “innovation valley of death.” The costs and additional business risks associated with prototyping, product development and design for manufacturing often are significant. Many innovations can be created in a laboratory setting, but they fail to reach the commercial manufacturing stage.

Startups might think that they have done the necessary engineering work for their product and are looking for someone to help them scale production. But what is required to make something in a lab can be far different from making a large number of that product in a manufacturing setting.

In order to overcome these challenges and commercialize a product, a startup will need to address Design for Manufacturing (DFM). It is not unusual for a startup to discover that they need to re-engineer their product in order for it to be built en mass. To address DFM, they should understand:

● What is required by contract manufacturers to make the product.

● How sourcing works for thousands of parts versus what they need to build a prototype.

● The importance of materials, quality assurance and more.

The MA operates like an incubator within an incubator

The MA is a foundational program that other accelerators can use. MA provides about 80% of the material to prepare startups for manufacturing. The niche accelerators can then address specifications and regulations related to their specialty, such as clean air or photonics.

MA’s approach has three key components:

● Instruction: Includes eight weeks of classroom instruction inspired by the U.S. Department of Defense Manufacturing Readiness Level (MRL) methodology. The MRL methodology assesses the maturity of a manufacturing process for a particular product or system. It helps to identify manufacturing risks and ensures that a product can be produced efficiently and cost-effectively before full-scale production begins.

● Documentation: Focuses on education and advice related to technical drawings, such as a Product Requirements Document, a bill of materials and a quality plan. These are needed in order for a contract manufacturer to figure out what it will take to build a product, whether they can do it and how much they should charge.

● Introduction: Exposes startups to ecosystems of local MEP Centers, technical experts, other accelerators, funders, appropriate contract manufacturers, suppliers, and more.

Methodology strives to reduce tech, business risks at each step

Startups often rely on their own intelligence to develop product prototypes. They figured out one way to build something, so they may have painted themselves into a corner if they need to re-engineer their product for manufacturing.

The MA process was developed to address these deficiencies. The MA process begins with an MRL assessment, which identifies gaps that need to be addressed. It also provides a roadmap for addressing technical gaps and business risks. The startup can follow this roadmap to build confidence with potential contract manufacturing partners as they determine what’s next and as they work toward a viable long-term relationship.

Contract manufacturers can also benefit from the MA process. Just as an MRL assessment can help startups identify gaps and create a roadmap, it can help contract manufacturers:

● Identify bottlenecks in their own operation.

● Develop a roadmap for their own maturity level of development with their processes.

● Train new team members and help them see a bigger picture for product development.

Success stories: Helping startups scale manufacturing

The Manufacturer Accelerator approach has been used with more than 120 startup companies at three different accelerators. Here are two success stories that illustrate how it has helped startups bridge the gap to manufacturing operations and production at scale.

AlgenAir

AlgenAir developed technology to improve indoor air quality. This includes removing the buildup of carbon dioxide (CO₂) that can lead to headaches and increases in allergy and asthma-like symptoms. Essentially, they created a microalgae that consumes CO₂ and helps to solve the problem of indoor air pollution with a focus on large indoor spaces, such as airports or convention centers.

AlgenAir had a theory, a patent and a core technology, but they needed help with manufacturing techniques. The MA connected their product designers with mechanical and electrical engineers, and their collaborative work led to a more efficient manufacturing process. AlgenAir went from a drawing on graph paper to an actual product in a very short time period. They have since installed a prototype with the Pittsburgh International Airport.

TKFabricate

TKFabricate developed technology to retrofit integrated HVAC systems for multi-family buildings. According to their research, millions of housing units in older apartment buildings have poor air quality and a high rate of energy use. TKFabricate’s innovative, all-in-one unit upgrades the control and monitoring systems for an entire building, yielding operational savings and increasing property values.

The solution makes it easier for building managers to perform regular maintenance without entering residents’ living spaces. It also reduces the interior space needed for HVAC-related equipment in each apartment. The MA helped TKFabricate address manufacturing quality control and assurance. The MA also connected them with the Rochester Institute of Technology, which has helped them reduce greenhouse gases.

Local MEP Centers can help bridge gaps in operation

Entrepreneurs who understand the demands of manufacturing increase their chances of successfully commercializing their products. Resources like NextCorps and the Manufacturing Accelerator can help innovators effectively convey their needs to manufacturers. Contact a local MEP Center to speak with an expert.

About the author

Mike Riedlinger, NextCorps

Mike is the managing director of Technology Commercialization for NextCorps, which is part of the MEP National Network.