We help product teams produce pilot batches: limited runs of hardware products used to validate manufacturing processes, assembly flow, QA/QC, packaging, logistics, and readiness for early customers before scaling to larger production volumes.
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.
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.
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.
Our team is eager to discuss how we can assist you and answer any questions you may have. Don't hesitate to reach out!
Through dozens of projects, we’ve learned what our work must include to ensure a high-quality pilot batch.
The list below is not exhaustive, but highlights what matters most.
For every unit to be built consistently, we prepare production documentation, testing procedures, fixtures, service instructions, packaging concepts, and traceability methods.
To define the most suitable approach for the first batch (materials, enclosure technology, manufacturing methods, fixation and assembly strategy, level of modularity, etc.), we need to learn your goals and success criteria first.
Leveraging experience from similar hardware projects, we help define the right product baseline, documentation, and production process to avoid unnecessary expenses and rework.
We ensure the design is DFM-ready, with production-oriented CAD models, validated components, and defined assembly procedures.
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Our rates are significantly lower than those of a typical US firm.
We work with startups and product teams worldwide and deliver hardware internationally.
Rather than juggling multiple vendors, you get the team who handles all necessary refinements across hardware, firmware, and manufacturing.
NDA by default. Full IP transfer
Pilot batch starts when a working MVP needs to become repeatable.
Most teams evaluate pilot production at a visible level:
The real risks appear when the same product must be assembled, tested, packed, and documented multiple times.
The MVP is functional, but repeated assembly turns our inefficient and costly.
Units look identical, but testing reveals inconsistent performance.
The batch is built, but documentation, sourcing, or process control are not ready.
Work that highlights the incredible technologies, solutions, and products EnCata developed
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.
designed and manufactured for pilot production
built and tested during the DVT phase
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.
increase in bar revenue
via credit cards and NFC-enabled transactions
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.
successful crowdfunding campaigns
features delivered in one device, replacing multiple single-purpose products
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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.
in the full mechanism
maximum speed
Our team is eager to discuss how we can assist you and answer any questions you may have. Don't hesitate to reach out!
We produce a limited batch of hardware units and generate the manufacturing feedback needed to reduce cost, defects, and process risks before larger production.
We review the MVP, documentation, components, enclosure, firmware, and assembly logic before production. If the product is not ready for a repeatable batch, we define what must be fixed first.
We spot yield issues, defect patterns, assembly bottlenecks, material concerns, packaging risks, and supplier feedback and provide you with the working solution.
Production tools, assembly fixtures, test benches, firmware flashing, calibration steps, and inspection checkpoints required to build and verify units consistently.
A limited number of production-intent units built for early customers, field testing, certification preparation, crowdfunding delivery, or manufacturing validation.
Pilot batch manufacturing often reveals tasks that need to be solved before, during, or after the first limited production run.
Manufacturability review; assembly simplification; material, tolerance, fastening, and enclosure improvements before pilot or low-volume production.
Design updates for enclosures, mechanisms, fixtures, tooling, assembly constraints, and parts that become problematic during pilot production.
Limited production runs for early customers, field testing, crowdfunding delivery, certification samples, or first market validation.
PCB, component, power, connectivity, and firmware-related improvements when pilot units reveal instability, sourcing risks, or test issues.
We serve as your all-in-one team, eliminating the need to coordinate with various freelancers or companies.
Deep domain understanding increases the success rate of your product.
Each pilot batch has its own scope, tooling needs, and production risks. However, once the MVP is stable and the design is ready for manufacturing review, most pilot batch projects fit within this timeline.
