From Sketch to Strategy: Real Lessons from Beyond the Sketch: Prototyping 101
From left to right: Moderator Mike Riedlinger, Speakers: Adam Baker - KHIO by Prolivio, Ben Zombek - BZDesign, Josh Sanders - Sanworks, Dan Steiner - Phlotonics, Jordan Sayegh and Frank Cavalier - CADimensions.
On March 26, founders, engineers, and curious builders gathered at NextCorps for the kickoff of Beyond the Sketch
- a new event series from NextCorps and BZDesign that dives into the practical realities of product development, starting with one of the most critical phases: prototyping.
Moderated by Mike Riedlinger, Managing Director of the Manufacturing Accelerator at NextCorps, the event featured a panel of local innovators who shared their unfiltered lessons from the trenches - from underbuilt prototypes to overengineered ones, and the strategic pivots in between.
Prototypes That Teach (and Sell)
Panelists Adam Baker (KHIO), Dan Steiner (Phlotonics), Josh Sanders (Sanworks), Ben Zombek (BZDesign), Jordan and Frank Cavalier (CADimensions) each brought a unique lens to the conversation — but the throughline was clear: a prototype is much more than a physical model. It's a tool for learning, pitching, validating, and aligning with partners and customers.
“We learned that we way overbuilt our product at first,” said Adam Baker, describing KHIO’s journey from scrappy metal prototype to sleek wearable cooling device, with support from the Manufacturing Accelerator.
Dan Steiner demonstrated how a beautifully executed prototype - condensing a process that initially required an entire room full of equipment - helped secure over $2.5 million in funding for Phlotonics.
Josh Sanders reflected on his evolution from neuroscientist and hobbyist to founder of a global instrumentation brand. “I quickly learned that you have to be a little more professional,” he said — a shift that began by working with local partners at NextCorps to bring polish and manufacturability to his designs.
Ben Zombek walked through how BZDesign worked with ibml to study floor-level workflows, resulting in ergonomic and functional improvements that improved daily use and long-term performance of the IBML Fusion Scanner.
Tools, Tactics, and the Power of Partnership
Jordan Sayegh and Frank Cavalier from CADimensions rounded out the panel, offering practical insight into the tools behind the builds - from SOLIDWORKS to the 3D printing equipment in the FabLab. Their guidance reminded attendees that early alignment between software, design, and fabrication partners can save significant time and cost later in the process. “The modern startup ecosystem, like what NextCorps offers, allows for rapid, low-cost failure in the digital realm before a single piece of metal is cut. As Jordan said, our job is to really help you in year one to get things off the ground and get some designs out there. Then, hopefully, we’ll see your product for sale in the market,” said Frank.
After the panel, attendees toured the NextCorps FabLab, discovering tools, printers, and support services available right here at the NextCorps FabLab in the heart of downtown Rochester. CADimensions and BZDesign were on-site to answer questions, and the evening closed with Startup Drinks, where attendees connected over shared challenges, new ideas, and concrete next steps.
What Comes Next
Whether attendees left with a better grasp of additive manufacturing, a new resource for funding, or a reminder to keep it simple, the night was packed with useful insight and honest reflection. And that’s exactly what Beyond the Sketch aims to deliver - real strategies that help product teams move with confidence, from idea to execution.
As Designers-in-Residence at the FabLab and long-time partners to innovators in the region, BZDesign is proud to co-lead this series and provide the design thinking that bridges sketchpad concepts to market-ready products. From early-stage prototyping to complex system design, our team supports companies of all sizes - including work on flagship systems like the Kodak Nexfinity Press.
Register Today for our next event on May 27 — Beyond the Sketch: New Product Development Resources for Manufacturers to learn how design, funding, and partnerships fuel growth for NYS manufacturers. We’ll highlight real-world examples of companies that leveraged design resources and funding to scale production, expand markets, and create jobs here in upstate New York.
Beyond the Sketch is just getting started, and we’re thrilled to continue building momentum with NextCorps to serve and support Rochester’s innovation community.