XXXBMX it varies a lot between models. I'd say 90% of the time the product manager will take an existing frame drawing and make alterations to it. It is then emailed to one of our factories to make the samples, which are shipped to our office in Dayton. Sometimes we may go through a round or two but normally we can get it in the first round. We also have a model shop in-house to make paint and component changes.
However, in the instance that we are doing something really out of the norm (ie. the extendeable rack on the Deluxe) we will make a prototype sample here in the states and send it over to be replicated. This happens a lot with the our kids products like trikes and scooters.
Oh and thanks, Guinness is a fantastic dog, couldn't ask for a better one.
-HuffyDesigner