From first idea to manufactured product
Julien Ayer Studio develops products in which form, function and construction are considered as one.
I work directly with companies, entrepreneurs and technical teams to transform early ideas, unresolved concepts and complex requirements into clear, coherent and manufacturable products.
My approach combines design sensitivity with hands-on technical development. Sketching, physical experimentation, advanced 3D CAD, prototyping and dialogue with manufacturers are part of the same continuous process. This allows the original intention to remain present as the product moves from an idea to something real.
Understand
Defining the right product
A project rarely begins with a perfectly defined brief. It may start with an intuition, a technical problem, an existing product that needs to evolve or several requirements that have yet to form a coherent whole.
Before designing a solution, I work with the client to understand how the product will be used, what it must achieve and which constraints will shape its development. The aim is to identify what is essential and establish a clear direction without defining the outcome too early.
This may include:
- Clarifying the product’s purpose and intended use
- Analysing functional and technical requirements
- Identifying opportunities for improvement
- Structuring an initial brief
- Defining the design direction
- Evaluating existing concepts or products
Explore
Product design
Ideas are explored through drawing, volume studies, digital modelling and physical tests.
Rather than treating appearance, function and production as separate subjects, I develop them together. Proportions are refined alongside ergonomics, construction, materials and assembly. This creates products with a clear identity whose form grows naturally from how they are used and made.
This may include:
- Concept generation and development
- Sketching and form exploration
- Proportion and volume studies
- Ergonomic development
- Functional architecture
- Material and finish definition
- Detailed product refinement
Develop
3D CAD and technical development
Three-dimensional modelling is not simply used to document a finished design. It is an active part of the design process.
Advanced CAD development makes it possible to resolve surfaces, interfaces, mechanisms, assemblies and manufacturing constraints with precision. Details are considered at the scale at which the product will ultimately be produced, while preserving the clarity of the original concept.
This may include:
- Advanced 3D CAD modelling
- Complex surface development
- Part and assembly design
- Construction and interface development
- Mechanism integration
- Design refinement for specific production processes
- Preparation of production-ready geometry
Test
Prototyping and iteration
A product must be experienced physically to be properly understood.
Prototypes reveal qualities and problems that cannot be judged on screen alone: scale, balance, grip, movement, resistance, assembly and the relationship between parts. I use models and functional prototypes throughout development to test decisions early and improve the design through direct observation.
This may include:
- Scale and appearance models
- 3D-printed components
- Functional prototypes
- Ergonomic and handling studies
- Assembly and mechanism testing
- Evaluation of proportions and details
- Iterative design adjustments
Communicate
Visualisation
Clear images help people understand a product before it exists.
I create precise visual material to evaluate design decisions, compare alternatives and communicate the intended result to clients, technical partners and manufacturers. The objective is not only to produce an attractive image, but to make the product and its construction understandable.
This may include:
- Photorealistic product renderings
- Concept and design-development visuals
- Exploded and assembly views
- Material and finish studies
- Technical illustrations
- Project presentations
Realise
Design for manufacturing
The transition from design to production is not treated as a handover at the end of the project.
Manufacturing considerations are introduced throughout development. Materials, processes, wall thicknesses, tolerances, fastening methods, assembly sequences and supplier capabilities all influence the final result. I collaborate directly with engineers, suppliers and manufacturers to resolve these questions while protecting the qualities that give the product its identity.
This may include:
- Design for manufacturing and assembly
- Material and process selection
- Construction-detail development
- Technical coordination
- Supplier and manufacturer dialogue
- Review of samples and production proposals
- Design follow-up during industrialisation
Designed to remain relevant
I believe a product should justify the resources, energy and knowledge required to make it.
Longevity begins with a product that works well, feels right and remains useful. It also depends on durable construction, considered material use, repairable assemblies and details that can withstand both time and repeated use.
These principles are integrated into the design process and adapted to the realities of each project rather than presented as a separate promise.
A direct and flexible collaboration
Every project requires a different level of involvement.
I can contribute to a specific question, develop an existing concept or accompany the complete process from the first sketches to production. Clients work directly with me throughout the project, allowing decisions to remain clear and communication to stay close to the work itself.
This direct relationship is particularly valuable when a project sits between creative ambition and technical complexity—and when neither can be resolved without understanding the other.