Rapid Prototyping in Action: Three FabLab Sprints, Three Fully-Realized Prototypes
The BZDesign team has been busy in the FabLab over the past few weeks, working closely with innovative startups to transform ideas into functional, test-ready prototypes. These sprints highlight our ability to quickly iterate, fabricate, and deliver high-quality design solutions that integrate seamlessly with our clients' evolving technologies.
Phlotonics I/O Control Box
Our first sprint was a five-week engagement with Phlotonics, a company developing cutting-edge optical switching technology. The result? A fully integrated I/O control enclosure that consolidated a single-board computer, a custom PCB, and a laser mount into one compact, organized package. Using a combination of 3D printing and laser cutting, we introduced a new fastening approach with heat-set inserts—allowing the enclosure to be opened, closed, and modified for future expansions with ease.
Sanworks PulsePal Redesign
Next, we teamed up with Sanworks on a three-week sprint to reimagine the enclosure for their PulsePal device. The goal: reduce part count, streamline assembly, and fit a newly updated electronics set. We developed and tested multiple sets of laser-cut and 3D-printed prototypes, fine-tuning the design to address fit and finish. The outcome was a sleek, production-ready solution that improves both usability and manufacturability.
Rapid Lens Mount System
Finally, we collaborated with a 2025 Luminate cohort team, to design a revised lens mounting system for their micro-lens testing. With just two days from prompt to shipment, we rapidly prototyped a modular mount that enabled clean, efficient component swapping. The delivered parts required no modification and immediately performed better than the initial test setup—proving that fast doesn’t have to mean compromised.
Rapid Prototyping, Delivered.
These projects demonstrate how our in-house prototyping capabilities and agile design process enable startups to move quickly without sacrificing quality. Whether it’s a five-week sprint or a 48-hour turnaround, the BZDesign team is built to deliver.