Pilot Batch Manufacturing After MVP

If you’re looking for a contractor to turn your MVP into a small batch of devices, our team will take it on. Limited hardware runs used to validate manufacturing processes, assembly flow, QA/QC, packaging, logistics, and early customer readiness before scaling up – we handle it all.

Pilot batches from 20 units
Up to 100 PCB assemblies per month
CE/FCC review included

When You Need Pilot Batch Manufacturing by EnCata

When you need someone who doesn't blindly ship an MVP to production

Before any pilot batch, our team reviews the MVP for manufacturing readiness and risks. Moving directly from MVP to larger volumes is risky, even if the product works.

When you need someone who will tell you the real state of your product

A pilot batch only makes sense if the product is ready. If your MVP still needs major changes, lacks stability, or isn't repeatable, we'll tell you directly.

When you need a technology specialist who is also an engineer

EnCata combines engineering and production technology in one team. There is no need to coordinate separate contractors for materials, methods, tooling, fixtures, assembly, or testing.

Product development life cycle

1

Discovery

Initial research phase that defines the problem the product will solve and how it will create value. At this stage, the team assesses current conditions — whether building from scratch or improving an existing system — sets the scope of work, and identifies risks or bottlenecks. The outcome is a validated concept, with impractical ideas discarded and a plan for addressing issues before and after launch.

2

Feasibility study

At this stage, we move from ideas to validated decisionsWe define a feasible product architecture, compare implementation options, and verify critical assumptions both technically and economically

3

POC

Tangible demonstration that an idea or concept is technically feasible. At this stage, The team relies on components and materials that are simple, readily available, and often temporary, such as basic breadboards, hobby-grade motors. The goal is to test key hypotheses, using minimal resources, and keep attention on the core objective.

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4

Prototype

Preliminary model of a future device that already performs its primary function. At this stage, the team employs more reliable and efficient components (e.g., advanced microcontrollers, high-quality motors, precision drive mechanisms). Unlike a PoC, a prototype typically has an enclosure, though it may not yet be finalized.

5

MVP

Functional prototype developed on the basis of engineering calculations, with an optimized BOM, custom-designed electronics, and uniquely engineered mechanical parts. It is intended for field or laboratory testing.

6

Pilot

Limited-scale production and deployment of the finished product to validate it under real operating conditions. At this stage, the team gathers user feedback, monitors performance in the field, and identifies any issues that only appear in day-to-day use. Insights from the pilot phase guide final adjustments before mass production.

Want to develop a custom solution?

Our team is eager to discuss how we can assist you and answer any questions you may have. Don't hesitate to reach out!

Book a call

Our approach to feasibility study

Through dozens of projects, we’ve learned what a feasibility study must include to ensure a fast and predictable transition into development.

The list below is not exhaustive, but highlights what matters most.

Architecture first

We don’t start with components, we start with system-level decisions

Different architectures can lead to completely different cost, performance, and risks

Early cost visibility (BOM & CAPEX)

We estimate component cost, tooling investments, and production constraints. This allows you to adjust the product before expensive mistakes are made

Clear and structured deliverables

You receive a feasibility report and technical specification ready for the next stage: architecture comparison and selected solution, BOM and P&L, identified constraints and key assumptions, scope of work with development plan and cost estimate.

Engineering aligned with business model

We link technical decisions to unit economics

Target price, margins, and production volume directly influence component selection and system design

Deep engineering without Tier 1 overhead

We deliver CE- and IEC-ready power systems at reasonable budgets.

The difference is not engineering depth. It is lower project overhead.

Reduced certification iterations

Our experience with power electronics and BMS development helps identify thermal, EMC, protection, and architecture issues early, reducing redesign cycles before certification.

Work globally, ship globally

We work with startups and product teams worldwide and deliver hardware internationally.

Certification-ready product

We develop power electronics and BMS with the CE, TÜV certification requirements in mind.

Expert Insight

What defines feasibility in hardware products

Feasibility starts with the right questions.

Most teams evaluate products at a visible level:
- What problem does it solve
- How it looks and feels
- Whether it can be built

This aligns with standard product thinking:

But in hardware, this is only part of the picture. The real constraints are not visible at first.

Architecture trap

A working concept that doesn’t scale

Cost gap

Product works, but unit economics break

Manufacturing mismatch

Design cannot be efficiently produced

Expert Insight

Featured projects

Work that highlights the incredible technologies, solutions, and products EnCata developed

View all portfolio
Vehicles

Custom IP66 Enclosure Design

EnCata developed a custom IP66-rated enclosure for automotive electronics, tailored to a specific PCB. We handled industrial design, DFM, in-house mold fabrication, pilot production, and assembly, delivering full-cycle development under one roof.

2 moulds

designed and manufactured for pilot production

10 prototypes

built and tested during the DVT phase

View Project
Consumer & wearable

Custom Smart Beverage Pourer

EnCata supported a startup as an engineering contractor, developing a smart beverage pourer for bars that meters each pour in real time, connects to POS and mobile apps, and enables NFC payments — from PoC to MVP. All IP belongs to the customer.

up to 50%

increase in bar revenue

250% faster payments

via credit cards and NFC-enabled transactions

View Project
Consumer & wearable

Custom IoT 5-in-1 Air Purifier

EnCata developed a multifunctional IoT device that purifies, humidifies, ionizes, and monitors indoor air. We supported a consumer startup as an engineering contractor — from concept and embedded software to pilot production. All IP belongs to the customer.

2

successful crowdfunding campaigns

5-in-1

features delivered in one device, replacing multiple single-purpose products

View Project
Consumer & wearable

Actuator Spinner Development

EnCata developed a hand-operated kinetic toy with a custom actuator mechanism that converts axial pressure into controlled rotation. We delivered the full mechanical product development cycle – from concept and ball screw design to TRL-7 prototype.

14 parts

in the full mechanism

2000 rpm

maximum speed

View Project
0
0

Want to develop a custom solution?

Our team is eager to discuss how we can assist you and answer any questions you may have. Don't hesitate to reach out!

Discuss your project
Expert Insight

What’s Included in a Feasibility Study

We evaluate your product from engineering, economic, and production perspectives to define a solution that can be realistically built and scaled.

Production feasibility

We assess manufacturing methods, supply chain, and scalability to understand whether the product can move beyond prototype.

Decision-ready documentation

We develop a structured feasibility report and technical specification covering architecture comparison, selected solution, and constraints. Includes P&L and SoW for the next development stage.

Cost modeling & unit economics

We estimate BOM, tooling investments, and production costs. Translate technical decisions into target price and margins. Identify key cost drivers and risks that affect scalability and business viability.

Architecture & concept validation

We define and compare possible product architectures.The goal is to select a solution that meets performance, cost, and constraint requirements

Meet EnCata Team

We serve as your all-in-one team, eliminating the need to coordinate with various freelancers or companies.

45+
team
5
business analysts
12
prototyping experts
Industries

We Design Across Various Industries

Deep domain understanding increases the success rate of your product.

Consumer & wearable

Consumer & wearable

96
projects delivered

Our team specializes in full-cycle consumer electronics and wearables development and manufacturing. Explore the page to see relevant project examples.

See how we deliver
IIoT & automation

Industrial IoT (IIoT) and Automation Hardware Solutions

15
projects delivered

EnCata will automate your production facility or warehouse with sensors, actuators, and edge computing, providing real-time data processing and efficiency.

See how we deliver
Industrial equipment & tools

Custom Industrial Equipment & Tools

243
projects delivered

Can’t find the right equipment? Discover how EnCata’s custom-built solutions tackle your unique challenges and enhance your production efficiency.

See how we deliver
Analytical & lab equipment

New Analytical & Laboratory Equipment Development

12
projects delivered

Explore EnCata’s custom solutions for analytical and lab equipment. Discover our precision design and development services—click to enhance your lab today!

See how we deliver
Agriculture

Custom Agricultural Hardware Solutions

8
projects delivered

EnCata helps bring your new tech in agriculture to life, including precision agriculture and robotic farming, turning your innovative ideas into reality.

See how we deliver
Green tech

Green Tech

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

See how we deliver
Healthcare

Healthcare

23
projects delivered

Expertly developed, tested, and manufactured devices ready for market entry. We guide your product through all stages to market. Go test our expertise!

See how we deliver
Robotics

Robotics Solutions for Cutting-Edge Automation

6
projects delivered

Custom robotics solutions for automation—robotic arms, AGVs, and more. Contact us to develop tailored robotics systems for your business needs.

See how we deliver
Smart city

Smart City

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

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Food tech

Custom Hardware Solutions for Food and Drinks

6
projects delivered

We develop custom solutions for food and drinks: from dosing and filling systems to quality control, and automated cooking systems. Contact us today!

See how we deliver
Vehicles

Vehicles

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

See how we deliver
Other

Other

projects delivered

This page is still under development. If you're interested in our experience in this field, please fill out the contact form and we’ll get back to you.

See how we deliver
FAQs

Frequently Asked Questions

Have a question that needs a human to answer? No problem.

Speak to our Sales Team now
What is a hardware feasibility study?
How do you determine if a hardware product can be built?
What is included in a hardware feasibility study?
How do you assess manufacturing feasibility?
What risks can a feasibility study identify?
How much does it cost to manufacture my hardware product?
When should I run a feasibility study?
What happens if my product is not feasible?
How is this different from a prototype?