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About Kyflo Design

What Makes Kyflo Incredible?

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End to End

Your one stop shop for product development

Experience a seamless end-to-end product design journey with our consultancy, spanning conception, development, and manufacturing. With a decade of expertise in electro-mechanical design, medical biosensors, and wearable electronics, we serve diverse markets, offering comprehensive services for successful market entry and growth.

Unleashing innovation, transforming industries. Your trusted partner for visionary product design and development.

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Product Development
  • Brand development
  • R&D
  • Patenting
  • Supply Chain
  • Product Manufacturing
Engineering
  • Mechanical Engineering
  • Electrical Engineering
  • Biosensor Design
  • Industrial Engineering
  • Manufacturing Engineering
Design
  • Industrial Design
  • Packaging Design
  • Graphic Design
  • UI/UX Design
  • Web Design
Consulting
  • Improving Existing Designs
  • Brand Strategy
  • Marketing
  • DFM/DFA
  • Brain-For-Hire

Inspiring innovation.

Crafting excellence.

Transforming ideas into reality.

Startups

Accelerate your startup's journey with Kyflo, an innovation-first design firm that unlocks growth by streamlining end-to-end product development.

Small Manufacturers

Unlock the full potential of your business, revolutionizing your product portfolio or optimizing performance with a decade+ of manufacturing design.

Enterprise

Stay ahead in today's marketplace, elevate your enterprise's innovation by reshaping products and driving competitive advantage

Optimized communication and low overhead

Redefining Product Development for Success and Efficiency

leveraging a vast network of vendors and specialty contractors accumulated over a careers worth of world-class product development. This translates to low design costs, focused specialty engineering, and efficient operations. Led by owner Kyle fredericks, Achieve incredible results without paying for your design contractor’s year round office space, high head count or bloated administration and management costs. Kyflo expands it’s engineering team remotely or locally with coworking spaces to meet the needs of your project while keeping consistent in the proven quality, design expertise and creative vision of Kyle Fredericks.

Kyle Fredericks

Owner & President

Kyflo’s Global Supplier & Manufacturing Network

Don’t be left hanging with other design firms, Kyflo’s design and engineering also includes a trajectory for mass manufacturing and optimal cost optimization for logistics.

Kyflo Design Toronto Office

240 Richmond St W, Toronto, ON M5V 1V6

Kyflo San Francisco Remote Office

San Francisco: 2 Embarcadero Ctr, San Francisco, CA 94111 Design office and Global US imports and distribution hub

China Manufacturing Hub

Kyflo China – Assembly and QC hub utilizing a local China supplier network. Certified ISO9001, ISO13485:2015, IATF 16949:2016 Suppliers include:

-sheet metal and casting -injection molding -Premium Packaging -Specialty components and hardware -Professional Prototyping & CNC -Micro hardware and sheet metal components -Electronics PCB fabrication and population

Textile Manufacturing Hub

India Textile Manufacutirng and Fabrication Hub

Logistics Hub & Port

Vancouver Port

Rotary Die Cutting and Medical Goods Packaging

Combined footprint of over 100,000 sq ft, automated converting processes. ISO 13485:2016 certified, ISO 9001:2015 certified, and operates multiple locations in the USA and Mexico

Medical Goods Manufacturing

Taiwan based Medical Manufacturing Partner Certified ISO9001, ISO/TS16949, ISO13485, QC080000, ISO14001, and OHSAS18001, as well as those of environment safety and hygiene and hazardous material management system. Lab has accredited ISO17025 by CNAS. Additionally ISO9001, ISO14001, ISO45001, IATF16949, QC080000, ISO13485 and ISO17025.

Low-Medium volume Fabrication

Medium volume quick turn CNC + Plastic part production certified ISO 9001:2015

Low-Medium volume Fabrication

Medium volume quick turn CNC + Plastic part production certified ISO 9001:2015

Medium volume Fabrication

Medium volume quick turn on-shore injection molding certified ISO 9001:2015

Understanding Kyflo's core principals

What drives us

Kyflo Design stands for engineering excellence, the belief that functional products can also be elegant and beautiful. Products should be designed for humans; targeting that spark of excitement when opening up a new gadget, the satisfaction of using technology that feels magical, the glimpse of novelty and awe when seeing a product do something new and unique, that powerful punch of “wow” when experiencing well made and well engineered products.

Products can be made differently, designed for cost efficiency and manufacturing streamline while also being elegant and high quality.

Kyflo Design is your one-stop shop for product design and fabrication. We can turn any idea into a high-quality product, from electronics to plastics to modern technologies. We also help you with branding, web, e-commerce, and logistics to get your product on the market and shipping to customers. You’ll work directly with Kyle Fredericks, a product designer with over a decade of experience, 50+ products designed and developed, 15+ patents, and numerous medical products and biosensors with FDA approval. Contact us today and let’s create something amazing together.

Conceptual Development: Illuminating Your Vision

In the exploratory phases, we delve into the art of bringing your innovative ideas to life. This journey involves an iterative and imaginative process aiming to visually encapsulate each unique feature within the overall design of your creation.

Kyflo Design Mechanical prototype and engineering Kyflo Design Mechanical prototype and engineering
Throwing everything at the wall to see what sticks

Albeit somewhat of a raw process, it serves as a powerful confluence of brilliant minds and ideas, fusing together to conjure the optimal solution for your product.

It’s an exploration of creativity to craft the best possible representation of your vision.

Reduce scope, dial in on the goal

Refined Concept

Building upon the earlier exploratory sketches and ideas, the refined stage consolidates all elements and design concepts into a comprehensive product sketch. This crucial phase focuses the goal, determines what is actually possible in the rhelm of technology and physics to achieve. It organizes thought and drives the business strategy. It’s a moment for reflective consideration, offering space for any final edits or adjustments before moving into the subsequent phases of CAD design, engineering, and prototyping.

Why a refining stage?

This stage enables quick adjustments, minimizing changes during CAD and engineering. It streamlines the process, ensuring a polished design, saving time, and maintaining alignment with your vision.

Reduce scope, dial in on the goal

Refined Concept

The journey from crafting a single prototype to manufacturing thousands of products is an adventure brimming with challenges. While creating one prototype might seem straightforward, scaling to mass production often reveals numerous unexpected complexities. At Kyflo, we understand this terrain well.

Why choose Kyflo?

Our track record boasts over 50 injection molding tools developed in the past decade. This wealth of experience instills a sense of trust and reliability in our clients. With our extensive design expertise, we spearhead the manufacturing of products at impressively low costs and high-performance standards, ensuring they endure the rigors of production, creating hundreds of thousands of parts aimed at long lasting performance. You can confidently place your trust in our proficiency and experience for a successful and cost-effective manufacturing journey.

3D Concept Design / CAD

Moving beyond the conceptual sketches, the CAD design phase is a transformative step. It involves harnessing cutting-edge 3D CAD software to construct the initial design of your product virtually. At Kyflo, we utilize industry leading, top of the line manufacturing-grade software such as Solidworks for mechanical engineering and Altium for electrical engineering for this crucial stage.

Where required, this may utilize contracted technical expertise for specialized areas of technology your product requires, ensuring a more streamlined journey through design and engineering only requiring specialized engineering muscle when needed.

This phase significantly eases the transition into the manufacturing phase, adding substantial value to the design process marking the pivotal transition from concept to a tangible, meticulously crafted product.

Examine & Refine

Simulation and Predictive Modeling

Our goal in this phase is to ensure the design is not only optimized for efficiency but also targets reliability within its intended environment. Through 3D virtual simulations, we aim to illuminate the limitations and enhance the design by testing it in various dynamic scenarios.

For instance, structural simulations enable us to determine the maximum load capacity, while material simulations identify weak points in plastic snap features which could be used to reduce manufacturing costs. Identifying these crucial mechanical elements is pivotal in crafting products that function flawlessly, ensuring reliable manufacturing processes, and delivering the ideal product version to your customers’ hands.

Iterate and Develop

Physical Prototyping

Kyflo Design Mechanical prototype and engineering

Hands-On Development

The CAD serves to verify the feasibility and functionality of the product design virtually. Moving to the prototyping phase, you’re presented with a tangible product, allowing a hands-on exploration of how it appears and operates in the real world. This stage is pivotal, as it offers the chance to assess the product’s physicality, understanding how customers interact with it. Not only does prototyping grant the opportunity to fine-tune and enhance the final design, but it also aids in minimizing costs and potential risks before transitioning to full-scale production. Our diverse prototyping methods, be it iterative, parallel, rapid, or streamlined, are meticulously crafted to ensure you’re well-prepared for user testing, investment pitches, crowdfunding, and every step in between.

While Kyflo does have a range of inhouse fabrication tools including Formlabs Form3 printers, capable of 25 & 100 micron  no-compromise prints, It is not always recommended to 3d print prototypes.

Sometimes, evaluating a products physical properties is critically important to the manufacturing process, how certain materials will perform under specific conditions, how parts mate, wear or interlock during assembly. These evaluations are better done using Kyflo’s various CNC prototyping vendors where parts are indistinguishable from final products.