This research study is based on a knowledge-transfer collaboration between The National Centre for Product Design and Development Research (PDR) and Markes International Ltd. The aim of the two-year collaboration has been to implement design tools and techniques for the development of enhanced thermal desorption products. Thermal desorption is a highly-specialised technique for the analysis of trace-level volatile organic compounds. This technique allows minute quantities of these compounds to be measured; however, there is an increasing demand from customers for greater sensitivity over a wider range of applications, which means new design methodologies need to be evaluated. The thermal desorption process combines a number of disparate chemical, thermal and mechanical disciplines, and the major design constraints arise from the need to cycle the sample through extremes in temperature. Following the implementation of a comprehensive product design specification, detailed design solutions have been developed using the latest 3D CAD techniques. The impact of the advanced design techniques is assessed in terms of improved product performance and reduced development times, and the wider implications of new product development within small companies are highlighted.