As stated in section 2.2, startups are not yet suppliers. Treating startups as suppliers is where most of the disconnect occurs in brand innovator relationships. Startups are starting out, you may both be on a long journey before they reach their destination.
In section 3.3 we highlight how traditional material innovation timelines are measured in decades. Historically those are based on chemistry, without the added complexity of biology. So understanding the timeline of each bio innovation’s product roadmap is essential to learning when and how to support.
If you are looking to solve a product need for next season or maybe even next year, working with an innovator who has yet to scale their process is unrealistic.
If you are taking a long view, looking for replacements or new product opportunities that you are betting could be strategically important to your future supply chain, start by understanding where the innovator is in their journey and how long they expect to take.
The above are common innovator needs for which there is currently a lack of R&D scale facilities and expertise. This includes down-stream processing, material science, wet-spinning, knit, weave, roll-to-roll manufacture. Early on innovators may be working with very small quantities of ingredients, fibers, sheet materials. These quantities will not be sufficient to run on scaled production lines.
Understanding how long it will take to go from quantities in the grams to kilograms, or centimeters to square meters, and the consistency and frequency with which these can be delivered, is central to brands knowing when they can start to deploy their own technical resources or those of their supply chain partners.
If the answer to the above questions is no, you need to factor more time for the innovator to undertake product development - you won’t be able to help them go faster.
A key challenge for startups is having the bandwidth to interface with dozens, if not hundreds, of interested potential brand customers. The smaller the team the more challenging it is for them to cope with a tidal wave of brand interest.
Add to this on the global brand side, the potential for outreach from multiple departments within the same organization causing confusion and wasting valuable resources for the startup trying to navigate the incoming. It is not uncommon for a startup to be contacted by a designer reaching out for samples, but also the investment team, the innovation team, the sustainability team or the sourcing team. This kind of uncoordinated, duplicative approach is inefficient for all.
Start by implementing an internal chain of command for innovation projects. Ideally, assign a relationship manager to the startup. This person should coordinate the project sharing with other teams within the brand, as well as be a single point of contact for the innovator.
Later in the process you may add supply chain partners. These partners need to know why this is an important project for you. Don’t step back at this point, the startup will likely need you to champion their cause with the supply chain partner. There will doubtless be challenges here that the brand at the center can influence positively in both directions.
Once you’ve identified the core team who will interface with the innovator, ensure everyone is clear what the material specification target is. This should be a collaborative effort. In some cases a startup may be working on a ‘drop-in’ solution, but in others they may have a novel material that needs new learning all round.
You may have specifications for analogous materials but how far do they fit this new material? What are the non-negotiables for performance, and where might your current materials be over performing? Understand every step of the technology, where are the challenges? Which part of the process is least developed? Do you have access to resources that could assist in any of those steps?
As mentioned in multiple places here, startups are not yet suppliers. The process of receiving samples needs to be understood in the context of a developing technology. In many instances, a material may still be years away from being ready for commercial implementation into your supply chain.
This means that, initially, samples should be interfacing with the team responsible for testing whether materials achieve the technical specification expected by the product team. There is no sense sending samples to the design team for feedback on touch or color if fundamentals such as tear strength or elongation to break have not been met. Subsequent development on composition or chemistry may also change look and feel and take months or years.
Design teams are used to seeing final materials that perform in the function for which they are intended. They expect to be able to request aesthetic changes, e.g. to color or finish. With fully developed materials that may be an easy iteration, for materials still in development that may be a distraction from more fundamental issues that still need solving. There may be limitations around what is possible in the short term and they may need to get comfortable with such restrictions.
Once consistent material samples reach the minimum performance criteria, in a regular quantity and size to make a product, it’s time to start prototyping.
If your manufacture is in house you will have insight and control over every stage of production with the ability to provide detailed feedback. This can be more difficult if the material is being sent to a remote manufacturer where English is likely not the first language, and where the nuance of failure may not be captured. Your manufacturer may be used to explaining product design failures but not the level of feedback an innovator needs to assess the composition or formulation of their material.
Understand the types of product application you’d like to target with a particular material (e.g. shoe, bag, small leather goods, garments). Share the typical production processes for each so the innovator can understand where and how their material may encounter stress and undertake development with this in mind. Prototyping is iterative and it will likely take many attempts to take a new material through a manufacturing process until you are happy with the end result. By establishing a formal feedback channel, learning will happen faster and solutions will be more readily found.
Finally, do you know the storage and shipping conditions a material may go through as it travels throughout the supply chain? Unstable materials may arrive or leave the factory in a different state to which they left you or the innovator.
Failures in manufacture may be due to one or more fundamental issues with the material composition, structure or chemistry. In some cases it’s at the prototyping stage where discoveries are made that require a complete rethink of one or more of those elements. Be prepared for further rounds of iteration on material development, which could take days, weeks, months or even years!
One last note, if you set biodegradation as a goal for the material’s end of life, but the construction or glue used in manufacture inhibits the product from being recycled or biodegraded, does that goal make sense?
Leather alternatives are often expected to drop into existing production lines where processes such as skiving are standard.
Materials that contain a high percentage of PU, rubber or other polymer may be challenged by this machine if they lack fiber structure.
Challenges with skiving also applies to materials that hold moisture or are dry compared to leather, the machine may chew or shred the material rather than shave a clean layer off.
A fibrous backing layer or internal scaffold may help.
Is this process essential or can the design and / or make be adapted?
If not, either the material may not fit the application (ever), or it may take further development (and wait time).
Stitching literally punches a hole in a material. In the case of fibrous materials such leather or textiles, the needle parts the fibers but the surrounding fibrous structure stops the thread from cutting the material. In leather specific needles are used adapted to the material.
In textiles, a line of stitching can be unpicked with the original stitch line disappearing or recovering, as the surrounding fibers close around the hole. Fiber structure is central to tear strength.
In materials without micro or macro scale fiber structure, stitching may punch a series of holes that cannot ‘recover’. It may be that the machine creates a line of holes that then tear, just as if stitching paper.
One mitigation for this is the use of a textile backer, or it may be fibers need to be added to the formulation matrix to improve overall tear strength.
Trying different needles, threads, stitch speeds, stitch lengths might all need to be explored to identify the most effective manufacture.
For footwear especially, materials may go through many aggressive processes. This may include exposure to high temperatures, high pressure, steam, etc.
The machine settings are likely set up for a specific material and so any material varying in composition or structure will likely encounter challenges. As with stitching, it may be that a series of experiments are run on each iteration of the material as it develops to learn how to improve bother the robustness of the material and the most effective settings for manufacture.
Cooperation form manufacturing partners is essential at this stage and gathering detailed feedback about failures can help further development iterations. Ideally capturing video as a material goes through a process enables the innovators technical team to study where and how it is failing and design solutions accordingly.
If you can invite your innovation partners to your manufacturing facilities to see production first hand this can be incredibly valuable.
Gluing is a key process in any product manufacture but comes with its own challenges.
As with other processes, it may involve heat and pressure that put materials under stress. Glue formulations may also interact with the surface chemistry of a material depending on whether it is water or solvent based.
An innovator may want to understand the particular formulation of the glue being used in order to understand any issues with adhesion.
Different glues may need to be tried in relation to a particular material to find the most compatible bond.
If you can source the glue and ship it direct to an innovator they can test in their own conditions as they iterate on material composition and chemistry.
Sources coming soon
Sources coming soon
Sources coming soon