Hardware Industrialization

Engineering Products That Scale

Helping hardware teams transition from working prototypes to scalable manufacturing.

TRUSTED BY STARTUPS, SCALE-UPS & INNOVATION INSTITUTES ACROSS EUROPE
Target Audience

Engineering for Real-World Manufacturing

I help founders and CTOs who need senior engineering support without hiring full-time. My focus is on speed, cost awareness, and reducing manufacturing risk before scale.

Hardware Startups

Pre-seed to Series B. Transitioning from functional prototypes to DFM-ready designs.

Medtech & Robotics

High-reliability systems requiring validation, precision, and manufacturing discipline.

Industrial SMEs

Modernizing products or resolving manufacturing and quality challenges.

Expertise

Services

Support across the full hardware lifecycle — from early concept to scalable production.

Product Development & MVP Validation

  • System architecture & mechanical engineering logic
  • Rapid prototyping for functional MVP validation
  • Risk analysis & design iteration based on testing

DFM, DFA & Costing

  • Process-specific DFM (Plastic Injection, Die Casting, CNC, Sheet Metal)
  • DFA & assembly logic to reduce part count
  • Cost breakdown analysis & material selection
  • Tooling feasibility studies for mass production

Industrialization & Supply Chain

  • Pilot series, pre-production, and mass production scaling
  • Global supplier sourcing, evaluation & technical alignment (Asia/EU)
  • Quality systems implementation & production line readiness

Strategic Advisory & Coaching

  • Hardware roadmaps & technical due diligence for investors
  • CTO-level support for high-stakes hardware decisions
  • Official Innosuisse Coaching framework for Swiss startups
Case Studies

Selected Projects

Real engineering challenges across industries — from R&D prototype to manufacturable product.

Industrialization & Supply Chain Strategy

Building the Factory Behind the Product

Building the Factory Behind the Product

Built complete in-house production lines from zero. Developed global supplier networks with proven track records qualifying manufacturers in China, Europe, and SE Asia. Served as Official Innosuisse Coach guiding startups through the transition from Prototype Phase to Industrialization Phase.

  • In-house production line built from ground up
  • Supplier qualification in China, Europe & SE Asia
  • Official Innosuisse startup industrialization coach
Key Result Reduced time-to-industrialization and increased supplier readiness
Robotics & Electromechanical Systems

Autonomous Drone, Exoskeleton & Electric Skis

Autonomous Drone, Exoskeleton & Electric Skis

Led full industrialization of autonomous security drones — building the global supply chain strategy from zero. Designed mechanical components for a robotic mobility exoskeleton with focus on production cost optimization. Integrated electric drive systems into winter sports equipment.

  • High-reliability motion systems with outdoor durability requirements
  • In-house production line built from zero
  • Global supplier coordination across Asia & Europe
Key Result R&D prototypes moved to functional, manufacturable units
MedTech & High-Precision Devices

X-Ray Imaging Device & Stroke Rehabilitation System

X-Ray Imaging Device & Stroke Rehabilitation System

Global manufacturing NPI engineering for radiotherapy devices — managing the full design transfer from R&D to production. Implemented DFM and continuous improvement processes for medical device assembly optimization.

  • Strict regulatory compliance: FDA/MDR standards
  • Zero-failure tolerance manufacturing processes
  • Precision assembly and validation protocols
Key Result MDR compliance maintained while optimizing production throughput
Aerospace & Automotive Interiors

Airbus A320 NEO Cabin & Automotive Interior Components

Airbus A320 NEO Cabin & Automotive Interior Components

Design Lead for Airbus A320 NEO family passenger cabins — lightweighting, safety regulations, and composite manufacturing. Designed tooling and equipment for aerospace composite production. High-volume plastic injection molding for automotive interior components across major OEMs.

  • Aerospace-grade composite manufacturing & tooling
  • High-volume injection molding for automotive interiors
  • Safety-critical design under strict regulatory frameworks
Key Result Aerospace & automotive engineering discipline applied to hardware scale-up
Advanced Wearables & Optics (AR/VR)

AR Glasses & Motorcycle Helmet AR/VR

AR Glasses & Motorcycle Helmet AR/VR

Developed complete hardware architecture for consumer AR glasses as co-founder — integrating optical modules with electromechanical housing into a lightweight ergonomic form factor. Integrated AR optics into safety-critical motorcycle helmet gear.

  • Full hardware architecture from concept to prototype
  • Complex optical system integration into wearable housing
  • Safety-critical AR integration for consumer gear
Key Result R&D prototypes to functional manufacturable units
Sports Performance & Consumer Goods

Bikes, Protection Gear, Goggles & Pumps

Bikes, Protection Gear, Goggles & Pumps

Ergonomic studies and DFM optimization for body armor using complex foam and plastic injection molding. Battery integration and internal cable routing for electric bikes. New material research and face-fitting studies for high-performance goggles.

  • High-volume Asian supply chain management
  • Ergonomics, aesthetics, and manufacturing cost balance
  • 37% per-unit cost reduction via DFM & tooling strategy
Key Result Scalable industrialization de-risking suppliers, production lines & costs
Trusted By
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About

Daniel Puerta Diaz

Senior Mechanical & Industrial Engineer

Based in Switzerland, I work with teams across Europe and Asia on the development and industrialization of high-tech hardware products.

My background spans aerospace, medical devices, robotics, automotive, and consumer sports equipment. I specialize in bridging the gap between engineering design and real-world manufacturing, ensuring products are robust, manufacturable, and ready to scale.

My expertise covers plastic injection molding, CNC machining, tooling, DFM/DFA, supplier selection, and cost engineering — with a strong focus on reducing manufacturing risk before production commitments are made. I bring deep expertise in DFM for plastic injection molding, helping teams optimize part geometry to avoid costly tooling modifications.

Throughout my career, I’ve led engineering teams, coordinated closely with external manufacturers in Asian ecosystems, and supported multiple hardware startups from early concept through to series production.

+15

Years Experience

Global

EU & Asia Network

Focus

Industrialization

Daniel Puerta Diaz
Get in touch

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