Driving innovation through in-house prototyping
PDM’s in-house engineering capabilities took center stage during the development of a unique, self-operating test tool. Built entirely in our own lab, this project marks a major milestone in our New Product Introduction (NPI) journey, demonstrating how full ownership from design to delivery can fast-track technical innovation and strengthen client confidence.
Our multidisciplinary team managed the entire lifecycle, from translating customer needs into detailed specifications, to system qualification and acceptance testing. The result? A complex, multifunctional tool that empowers the client to test subsystems more reliably and identify issues early, well before final system integration.
challenges
The client needed to validate subsystem assemblies before they were incorporated into larger machines. Standard tools wouldn’t cut it. Each test required electrical checks, vacuum control, pneumatic flow testing, and more. Accuracy and automation were key.
The goal: design and build a bespoke, self-operating test system that could simulate real-world production conditions and pinpoint quality issues at the source. PDM was asked to take full control, from concept to on-site commissioning.
PDM'S APPROACH
We applied our full-scale product development capabilities to deliver this advanced, one-off system. Every discipline—mechanical, electrical, and software—played a critical role.
- System design & requirements mapping: PDM started by converting customer requirements into detailed system specifications. Through structured System Requirements Analysis (SRA), the team ensured all functional needs were captured.
- Design & engineering: Using MCAD and ECAD tools, the team designed a fully integrated system combining mechanics, electronics, and software. Custom PLC software was developed to automate test procedures and ensure system flexibility.
- Certification & compliance: To meet European safety standards, a full CE certification process was followed. This guaranteed compliance while future-proofing the tool for broader deployment.
- Supply chain & assembly: A smart supply chain strategy ensured quality and speed. All components were sourced and assembled in-house at PDM, maintaining tight control over timelines and quality.
- Testing & commissioning: The tool was first qualified in our lab and then delivered for final Site Acceptance Testing (SAT) at the client’s facility. With SAT successfully completed, the tool transitioned into service support mode.
results & impact
The project delivered a high-end, purpose-built test tool—on time and without major scope changes. Results include:
- Fully automated testing of subsystems, increasing precision and reducing risk
- Earlier detection of quality issues in the production process
- Seamless project delivery, from design to on-site commissioning
- Integrated mechanical, electrical, and software elements, showcasing PDM’s in-house capabilities
- Stronger client confidence, built through collaboration and full lifecycle ownership
“This wasn’t just a machine, it was a proof point of what PDM can do when we bring all disciplines together. From spec to service, our team delivered.”
The system is now operational, and PDM continues to support the client through a tailored service level agreement, covering spare parts, troubleshooting, and upgrades.
conclusion
By fully owning the design, development, and delivery of a unique test system, PDM accelerated innovation for both the client and internally. This project highlights our ability to engineer complex systems in-house, reduce technical risk, and bring new tools to life faster.
Curious how PDM can help you solve complex engineering challenges with tailored solutions?
Get in touch to explore how our multidisciplinary teams can help you innovate with confidence.
Or are you excited to help build custom machines like this?
As a Sr Engineer at PDM, you’ll work hands-on helping clients improve performance, reduce complexity, and design the future. Ready to grow by doing, together with our clients and colleagues? Join us!
