Product & Process Engineering at Fusion focuses on converting concepts into manufacturable products and on establishing robust, repeatable processes that deliver quality, yield, and cost targets. We couple design-for-manufacturability (DFM) principles with process characterization, control strategy development, and documentation to ensure a smooth transition from R&D to production. Our engineering work is practical, compliance-aware, and geared toward reducing time-to-market and minimizing rework during scale-up.
Fusion’s product and process engineering engagements produce tangible technical outputs intended for direct handoff to operations or manufacturers:
Common engagements include: new product introductions (NPI) where Fusion supports DFMA and line design; process troubleshooting to address yield loss or variability; scale-up from pilot to full production; and transfer of design to contract manufacturers or internal plants. We also lead process simplification and cost-down exercises for mature product lines.
Our engineering approach balances speed with rigor:
We employ industry-standard and practical engineering tools to accelerate decision-making and documentation: 3D CAD (SolidWorks / Creo / CATIA), tolerance analysis tools, lifecycle PLM basics, process simulation tools, root cause analysis (8D), statistical process control (SPC), and DOE (design of experiments) for process optimization. Our teams are comfortable operating within client toolchains and can adapt to proprietary PLM or MES contexts.
Typical team composition for a Product & Process engagement includes: Manufacturing/Process Engineers, Product Design Engineers, CAD/Design Specialists, Quality/Validation Engineers, Test/Fixture Engineers, and Technical Project Coordinators. For scale-ups we add commissioning technicians and line leads to support physical execution.
For regulated sectors (medical device, pharmaceutical equipment), our engineering deliverables are created to satisfy audit and regulatory expectations: traceable design history files, validated process parameter records, documented verification & validation protocols, and risk management outputs (per ISO 14971 or client-specific frameworks). We coordinate closely with quality and regulatory teams to ensure process artifacts map to required submissions and inspection readiness.
Clients engaging Fusion for Product & Process Engineering typically realize: shortened design-to-manufacture timelines, reduced assembly complexity, lower scrap and rework rates, predictable yield improvements, and clearer documentation that simplifies supplier onboarding and audit response. Our focus is practical engineering that converts technical work into measurable production benefit.
We provide capability, problem-solving, and services — with speed and cost-efficiency at the core
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