From prototype to production: Why Collaboration makes the difference

From product development and electrolysers to the power of collaboration within NXTGEN Hightech Energy. We spoke with Arjen Vos, Managing Director of Brabant-based development and manufacturing company Verbi Gereedschappen B.V. from Helmond.

Verbi has been building high-quality moulds for the plastics industry for more than forty years. From concept to production, the company supports customers in ensuring manufacturability and precision, with expertise in CNC milling, turning, grinding, wire EDM and sinker EDM. Within NXTGEN Hightech, Verbi collaborates with partners on new production concepts for electrolysers, an example of how traditional craftsmanship and innovative energy technology come together.

Where does Verbi stand within NXTGEN Hightech Energy?

Within NXTGEN, Verbi is working on scaling up an electrolyser component. “The scale model, material selection and mould design are currently under development. The next step is to demonstrate that flatness and strength can be guaranteed under production-like conditions, and that the knowledge can be transferred to larger production lines,” explains Arjen Vos. In parallel, Verbi is investing in sensoring, connectivity, batteries and plasma applications, combinations of knowledge and manufacturability that are essential for the energy transition.

Towards hydrogen: thin, flat plates for electrolysers

Through long-standing relationships within the manufacturing industry, Verbi was brought back into the picture. There was a need for a thin, flat plastic plate serving as a separating component in an electrolyser—well aligned with Verbi’s core competencies. In the past, the company had already developed glass-fibre-reinforced ultra-thin plates for fuel cells.

Together with partners (including from the Chemelot ecosystem), Verbi mapped out materials, processing methods and mould concepts. The core challenge lies in the nature of plastics: they tend to warp, especially when deviating from a simple, round geometry. Filling patterns create weak points at corners and around holes—exactly where adhesion and strength are critical. Drilling holes in sheet material is possible, but not suitable for mass production. The real challenge, therefore, is to develop both the process and the tooling in a way that ensures flatness, adhesion and flow simultaneously.

“We have drawings for a scale model and several promising material directions,” Arjen continues. “The focus is shifting towards electrolyser components, as this is simpler and more efficient than combining them with battery applications. Realistically, full-scale mass production will require larger production lines than are currently available in the Netherlands. Our role therefore ends at a production-ready prototype and transferable process knowledge.”

Thinking along from the very first idea

Verbi enjoys being involved from the earliest stages of product development. “People come to us with very specific questions. Sometimes they are isolated issues, such as: Can this product be injection-moulded? What can I measure with sensors in my mould? More often, it concerns the entire trajectory from idea to a manufacturable product,” says Arjen Vos. “That is what we enjoy most: thinking along from the very first prototype and working towards a scalable, functional product. The best moment? When you unexpectedly come across the end product ‘out in the wild’.”

From sambal jar to dog chew—and a toothbrush

One example Arjen regularly encounters ‘in the wild’ is a sambal jar that does not leak. “We didn’t manufacture the jars ourselves, but we did design the way the jar and lid connect so that it seals properly.” In the end, around 80 million of these were produced.

Another success story originated from a product that initially failed. It started with a material based on potato starch, originally intended for disposable chip trays. Financially, the concept did not work out. “Together with a Wageningen alumnus, we added flavour and scent compounds to the potato starch. Granules were produced for injection moulding, and we tested the material using our moulds. The resulting test bars turned out to be very appealing to dogs. The real breakthrough came when we asked ourselves: why does someone buy a dog chew? Because it is good for a dog’s teeth. So we designed a product that is a chew on one side and a toothbrush on the other. The concept went global. Years later, the company was sold but the pride remains,” Arjen says enthusiastically.

How do you innovate as an SME?

Verbi has managed to continue innovating over the years, something that is not always easy for small and medium-sized enterprises. Arjen’s advice to other SMEs is clear: “Let go of the Calimero complex and embrace your strengths.” The Calimero complex refers to the feeling of not being taken seriously because of a company’s size. “In reality, small companies win on flexibility, craftsmanship and speed. Actively seek collaboration with fellow SMEs, educational institutions and regional initiatives.”

This mindset has already led to the establishment of a foundation that promotes technology among young people, a joint vocational training program in Deurne, and an innovation environment focused on sensoring and connectivity. “These are all things you would never start on your own but together with others, you absolutely can.”