This study aims to present a methodology that is step-based and uses both virtual and physical prototyping to improve product performance at the early stage of its design. While virtual prototyping is used to develop variants and to explore in detail the internal parameters of the design, physical prototyping, and testing are used to validate results. The proposed methodology uses numerical methods (Computational Fluid Dynamics (CFD) in the presented example) to obtain data for design characteristics and to improve them. This is demonstrated through a product development process of a new design for EGR (Exhaust Gas Recirculation) valve, where a decrease in pressure loss is searched as well as improvement and linearization of its actuation when mixing gases. Numerical simulation results are obtained (mass flow values at different positions of the valve, pressure drop values for both flow directions, etc.) that are compared finally against values measured over physical prototypes. Good correspondence between measured on physical prototype and calculated using virtual prototypes data is found. Besides verification and validation of the proposed methodology, a ready-to-manufacture product is developed with improved material and space usage and correspondence to the technical specifications. The developed new design of the EGR valve forms a contribution to decreasing the formation of pollutants by optimizing combustion in engines. [ABSTRACT FROM AUTHOR]