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Our Process

Our Process

Balonbay focuses on taking a step-by-step approach to every project. By progressing through projects methodically, it helps eliminate errors and also helps achieve the best design possible through the process of elimination. Below is a breakdown of our specialized workflow, listed step-by-step, with brief explanations of each phase.

Project Brief and Research

The brief normally takes place at the first meeting, and the purpose is to fully understand the objective of the project and involvement. Once these factors are determined, a project timeline is laid out along with the corresponding phases. The brief will also dictate which phases are necessary.

2D Sketch Development

Projects that involve creative development, such as creating a new product, begin with 2D sketch development. Within this phase, numerous pencil and digital sketches are created to explore different possibilities and solutions for the project. Sketches are relatively quick and helps put ideas and concepts onto paper. The sketches will also assist in determining if 3D laser scanning is required and the involvement of the scanning session.

3D Laser Scanning

As pre-determined earlier in the brief or sketch development, the 3D laser scanning session will acquire all the necessary data for the project. Scanning objects range from full-sized vehicles, small-scale clay models, motorcycles, to a series of small objects or fixtures. Normally if 3D laser scanning is required, the 3D CAD design phase cannot begin until the laser scanning is complete and reverse-engineered. For more detailed information on 3D laser scanning, please see this page.


Once 3D laser scanning is complete, the necessary data is reverse-engineered and re-surfaced. The exact amount and areas of re-surfacing is predetermined in previous phases. This gives us the accurate information needed for the next phase, 3D CAD modeling. For more detailed information on reverse-engineering, please see this page.

3D CAD Design

CAD design is the process of creating (or re-creating in the case of repair replacement parts) a new design in 3D space. 3D CAD is the phase where we translate the ideas and 2D designs into virtual geometry, formed by complex shapes and surfaces. The 3D CAD data can be represented as photo-realistic renderings, which helps visualize the end product. This phase is vital in the design development process because the 3D data is WYSIWYG (what-you-see-is-what-you-get), and is often the crucial opportunity to make final changes and adjustments.


The completed 3D CAD design is then programmed for rapid prototyping or 3D printing. The prototype helps us fully understand the physical geometry and surfaces, which would be otherwise difficult to do on a computer or in 2D graphics. The printed parts give us the ability to physically install and test-fit parts, allowing us to analyze if any changes or adjustments are required – either to improve the functionality or resolve an unforeseen issue.

Review and Finalize

Upon completing the phases listed above, the project is ready for finalizing and for engineering and manufacturing.