Engineering
ideas
into reality.
From initial concept sketch through to production ready CAD, our product development services cater for manufacturers and entrepreneurs across the UK and Europe.
We invest in the latest 3D CAD software and prototyping hardware to make sure we have the right tools for the job. In‑house, we have provision for 3D laser scanning and 3D Printing which is suitable for design validation and even batch runs of production parts.
A complete design & engineering service
From concept exploration through to production drawings and manufacturing support — we offer as much or as little as your project needs. We work as a standalone resource or as an extension to your existing team.
As design consultants we tackle R&D projects which address technical uncertainties, often working for and alongside research partners and clients with industrial specialisms.
Full Service Detail →
Concept Design
Rapid idea generation and visualisation. Exploring forms, mechanisms, and options before committing to engineering detail.
3D CAD (SolidWorks)
Production-grade parametric 3D models, assemblies, and 2D control drawings with full dimensional and material specification.
Prototyping
In-house 3D printing up to 500×500×500mm. Fast, accurate physical models for form, fit and function evaluation.
3D Scanning
Reverse engineering of existing parts. High-accuracy scans to reproduce, modify, or base new designs on legacy geometry.
Grant Applications
Over £175k of R&D grant funding secured. We help clients identify and apply for InnovateUK and design grants.
Manufacturing Support
Production quotations, quality guidance, and liaison with UK, European, and Far East manufacturing partners.
Your first product
brought to life.
DownloadEntrepreneur Guide
With over 25 years of experience we can guide your idea from sketch to a manufacturing-ready design.
Past experience includes:
- Lifestyle and consumer products
- Mother and baby
- Sporting goods
- Healthcare and living aids
- DIY and industrial tools
- Toys, games and education
- Get in touch to learn more
Flexible R&D for
your team.
DownloadSME Guide
With over 25 years of experience we can guide your idea from sketch to a manufacturing-ready design.
Past experience includes:
- IP-rated electronics enclosures
- Medical and laboratory equipment
- Signage and kiosk systems
- Military and industrial
- AV and consumer electronics
- FMCG and structural packaging
- Get in touch to learn more
"James managed a team of designers and technicians and was responsible for product design over a range of Audio Visual brands. An important part of his role was to ensure projects were managed to time and budget."Dr Mark CollingwoodDirector — Armour Home Electronics
"Reliable, trustworthy and responsible. He is creative and able to communicate his design concepts effectively through the use of 3D CAD and rendering software. Hard working and extremely personable."Tony LeeOwner — Lee Design Associates
"James has supported R'Care with both his creativity and technical ability to develop a family of new products for us. Working with European manufacturing partners he developed attractive and economic products."John GoughDirector — R'Care KFT
Let's talk about your project.
Your first conversation is always informal — no sensitive details needed before an NDA is in place.
Get in TouchOur process
A proven methodology refined over 25 years.
We work with you to set an agreed schedule of work, specific to your needs.
Specification
Agreeing a development timeline and product attributes. Competitor analysis and definition of specific performance metrics — the foundation for every good project.
Concept Design
Initial ideas for the look, feel and mechanism of a product. Sketches, early CAD visualisations and physical mock-ups to explore a broad range of directions quickly.
Concept Development
Adding engineering detail. Turning preliminary CAD into 3D parts that fit together — materials selection, tolerances, and manufacturing feasibility are introduced at this stage.
Prototyping
Physical exploration and evaluation. In-house 3D printing delivers models in hours. For high cosmetic quality we use professional model-making agencies. We evaluate strength, ergonomics, and assembly.
Design Development
Iterative refinement based on prototype learnings. Control drawings prepared and revised. Revision control, critical dimensions, BOMs, material specification, and tolerances are locked down.
Marketing Visuals
Photorealistic renderings to sell the product before manufacture. These serve investor presentations, crowdfunding campaigns, and patent applications.
Production Quotation
Engaging factories in the UK, Europe, and Far East for accurate guide manufacturing costs. We draw on a trusted network of manufacturing partners built over decades.
IP, Quality & Testing
Recording and protecting intellectual property. Safety, compliance, and packaging and graphic design support for a complete product launch.
Our commitment to your project
When we join an existing team we go the extra mile. This is what that looks like in practice.
Cost reduction
Recommending design or material changes that reduce manufacturing costs without compromising the brief.
Grant funding
Identifying and applying for R&D and design grants. Over £175,000 secured for clients in the last three years.
Client representation
Representing your company in supplier and manufacturer meetings — we protect your interests at every stage.
IP guidance
Advising on design registration, patents, and trade marks. We work with specialist IP solicitors when needed.
Exit strategy
Thinking beyond the product — how to structure a project so it has maximum value if you later sell or license.
Manufacturing partners
Access to our established network of trusted UK, European, and Far East prototyping and production partners.
We take intellectual property seriously.
We will never ask you for sensitive details about your project before an NDA is in place to protect your idea. Our first conversation will be broad — to discuss your requirements and for you to hear about our relevant experience. If it makes sense to work together, we'll send our standard NDA and arrange a meeting.
Start the conversation →
Selected work
A selection of projects spanning over two decades.
We pride ourselves on the breadth of experience we have built up over a great many years. Successfully working alongside in-house teams and as an independent design consultancy.
Our clients range from large international companies, educational establishments, start-ups, and established SMEs through to entrepreneurs and individuals working on small personal projects.
Your questions,
answered.
James Barr
BSc (Hons)
Product designer and engineer. Consultant since 1999.
Director of James Barr Design Limited since 2014.
Based in Surrey, working across the UK and Europe. Specialist in 3D CAD product design, reverse engineering, rapid prototyping, and new product development.
25+ years of commercial experience
James has been a consultant designer since 1999, working in a wide range of industries as both a consultant and in-house senior designer. James Barr Design Limited was established in 2014 to work directly with clients both large and small.
With a network of trusted manufacturing partners, we have great experience prototyping and manufacturing finished products. Consultancy work requires the ability to research and quickly understand any product's unique challenges and opportunities.
We specialise in CAD product design in Surrey, London, Kent and Sussex — but take on clients across the UK and Europe. Communication is key for remote working; clients are regularly updated through video calls, phone calls, and email.
Technology & Equipment
& high resolution resin
and Blue laser
Access control, nuclear inspection, sporting goods, fragrance devices, medical disposable diagnostics, laboratory equipment, oil industry, construction equipment, DIY, marine safety, mother and baby, toys, martial arts, military tripods, high-end audio amplifiers, loudspeakers, AV systems and home automation, FMCG packaging, transport, education, furniture, medical equipment handling, patient entertainment, consumer electronics, lifestyle products, sustainable products, security, process containment, industrial machinery, healthcare rehabilitation, barcode scanning, industrial work-desks, signage, point of sale, digital wayfinding, motorsport advertising, car care, dental PPE, flight simulation, household goods, exhibition planning, wound care, luggage, petro-chemical, building and trades, cryogenics, industrial 3D-scanning, plush toys, airsoft, mountain bike accessories, home security, promotional gifts, gaming accessories, keyboards, pet care, souvenir vending machines, kitchenware, water purifiers, building site safety, food delivery, motion detection sensors, boxing pads, drinks bottles with integrated electronics, candles, commemorative coins and plaques, food packaging, hotel reception entry-phones, binaural loudspeakers, microphone stands, custom wristwatches, curtain fixtures, architectural models, golf clubs, air suspension, custom car parts, POS payment terminals, historic reproductions, alcoholic beverage packaging, phone cases, aerospace maintenance…
Let's talk about
your project.
The first conversation is always informal. We'll discuss your project in broad terms — no sensitive details required before an NDA is in place.
Redhill Aerodrome
Kings Mill Lane
Redhill
Surrey
RH1 5JY
You can also reach us directly on 07971 391178 or at contact@jamesbarrdesign.co.uk.
Thank you.
We'll be in touch shortly.
Our partners
We work with a carefully selected group of partners to offer our clients a complete
end‑to‑end service — from prototyping and IP protection through to full production.
3DPRINTUK
Whilst we have an enviable selection of in-house prototyping machines, it is always important to use the right tool for the job. For larger batch runs and where particular surface finishes are required we are proud to partner with 3DPRINTUK.
www.3dprint-uk.co.uk →
AgileIP
Since 2004 we have been using AgileIP (based in Croydon, South London). They have provided assistance for us and our clients with all aspects of intellectual property — including registered design rights, UK and international patents, trademark and copyright.
www.agile-ip.co.uk →
Production in China
There are pros and cons to manufacturing your product here in the UK versus elsewhere in the world — something we are happy to discuss with you. Historically, tooling and production costs in China are significantly lower than in the UK.
We have access to a number of factories in China and will match your project to their key skills. Any international partners will have already been vetted for:
Clear, reliable and responsive throughout
Attention to detail with approved quality management
Assembly, finishing, printing, painting, packaging and shipping
Injection moulding tooling
Tooling
High quality products come from following a tried and tested process. This includes DFM (Design for Manufacture), mold flow optimisation, and great technical attention to detail when CNC machining the tools.
Production
Access to partners offering a wide range of technical services — including low volume tooling, insert moulding, over-moulding, and the specialised materials and surface finishes required for automotive and medical devices.
Take the next step
If you have an existing product in development and want to see how affordable tooling and production can be, or if you need specialist 3D CAD, engineering or prototyping support, get in touch for an informal chat.