Mechanisms with a purpose
Define the motion, load paths, friction, sealing, and wear that matter. Use early research, calculations, mockups, and test rigs to examine the riskiest assumptions before committing to detailed geometry.
Mechanical engineering & prototyping
Make it fit.
Make it move.
Make it work.
Parts, mechanisms, enclosures, fixtures, and complete physical products—from the first sketch to an assembly you can put on the bench.
Purely mechanical projects belong here, too. Whether your product contains a circuit board or runs entirely on gears, springs, and human effort, we work from the function it needs to perform.
01 / Function first
Engineering starts before the CAD model.
A shape is only useful when it works in the real world. We begin with the loads, movement, environment, users, and production constraints that will shape the design.
Production-aware decisions
Choose materials, tolerances, fasteners, part splits, and manufacturing methods with assembly time, tooling, part count, serviceability, and unit cost in view.
Whole-product integration
Map the interfaces with electronics, firmware, sensors, wiring, actuators, cooling, and the enclosure. Reserve space for connectors, adjustment, maintenance, and the tools needed to assemble it.
Evidence behind the design
Use appropriate calculations, simulation, material review, and physical tests to investigate loads, heat, vibration, motion, and repeated use. Record the conditions and limitations behind the results.
Need a demonstration on a short schedule? We can scope a bench model, visual model, or functional assembly around the questions your audience needs answered. Appearance, function, and production realism are agreed before the build.
02 / Technical scope
From parts to moving systems.
A project may need one discipline or several. We define the methods, fabrication route, and any specialist or supplier involvement around the work.
CAD, Simulation & Architecture
- 3D CAD structure
- Mechanism design
- Virtual prototype simulations
- Reverse engineering
- 3D CAD modeling
- Parametric assemblies
- Surface modeling
- Sheet metal design
- Welded metal structures
- Plastic part design
- Enclosure and cabinet design
- Mechanical fixtures and test rigs
- 3D scanning
- Kinematic simulation
Materials & Structural Analysis
- Part/material selection
- Analysis and simulation (stress, thermal, flow)
- Testing and material review
- Strength calculations
- FEA / FEM
- CFD
- Thermal calculations
- Safety factor evaluation
- Vibration analysis
- Load path analysis
- Mold flow analysis
Manufacturing, Sourcing & Reliability
- Manufacturing feasibility & manufacturing instructions
- Engineering risk assessment
- Failure mode assessment
- Procure and inspect parts
- Source and qualify suppliers
- Supply strategy plan
- Design transfer
- QMS regulatory documents & quality specifications
Builds & Hardware Testing
- Alpha prototype builds
- Verify part function specifications
- Model and prototype testing
- Product quality review
- Third-party test coordination
Mechanisms and motion
- Drives and gearboxes
- Pneumatics and hydraulics
- Robotics and animatronics
- Complex kinematics
- Suspension units
- Actuators and transmission systems
- Rotating assemblies
- Test benches and industrial tooling
- Motion conversion mechanisms
Manufacturing and engineering records
- 2D drawings
- Bill of materials
- Tolerance stack-up
- DFM / DFA review
- Manufacturing cost estimation
- PDM workflow
- Design documentation
- Applicable ISO drawing and documentation requirements
- Assembly instructions
- Inspection criteria
03 / Build the evidence
Four steps toward a repeatable product.
Start at the maturity your project has reached. The next build should answer a specific question, with a defined review before the following investment.
- 01
Concept prototype
Can the mechanical principle work?
A bench mockup, simplified mechanism, printed part, or early layout demonstrates core motion, fit, load path, or enclosure logic.
Focus: Spatial validation, feasibility, risk identification, and concept comparison.
What you receive: A model or test rig, findings, and a recommended direction.
- 02
Functional prototype
Does it work as a physical assembly?
Key parts, fasteners, interfaces, and moving elements perform the main mechanical function under controlled conditions.
Focus: Kinematics, ergonomics, component fixation, friction, sealing, and assembly logic.
What you receive: A functioning assembly and a record of what it demonstrates.
- 03
Validation prototype
Does it meet the engineering requirements?
Representative materials, tolerances, joints, and interfaces support tests of strength, heat, vibration, wear, stability, and repeatability.
Focus: Load testing, thermal behavior, tolerance stack-up, and integration with electronics where applicable.
What you receive: Test results, revised design information, and remaining risks.
- 04
Pilot-ready design
Can the next build be repeated?
Near-final parts, drawings, BOM, and assembly methods prepare the product for a controlled pre-production build.
Focus: Manufacturability, assembly workflow, cost reduction, inspection, and production transfer.
What you receive: Supplier-ready files and an agreed plan for the pilot build.
Schedule and price depend on complexity, materials, quantities, lead times, and the test work required. We establish the scope and estimate for your project before work begins.
04 / From screen to bench
Build, inspect, assemble, refine.
We choose the build process to suit the question: a quick fit check, a convincing demonstration, an engineering test, or preparation for production.
Model and prototype builds
Procure and inspect parts; verify critical part specifications; make bench models, rapid prototypes, alpha assemblies, and interface mockups. Use virtual prototypes where they can reduce uncertainty, and plan onsite work when the project needs it.
Fabrication and finishing
In-house work includes FDM and resin printing, laser cutting and marking, CNC machining, woodworking, and metalworking. We machine, hand-finish, and fit parts to the intended shape, color, texture, and feel. Specialist processes and larger tooling can be sourced.
Material and finish options
Evaluate additive manufacturing, machining, sheet processes, vacuum forming, casting, and molding against geometry and quantity. Bead blasting, anodizing, brushing, polishing, and coatings can be specified and coordinated to suit the selected material.
Evaluation and improvement
Check mechanical fit, clearances, motion, stress, heat, flow, and failure modes as required. Debug features, refine quality specifications, coordinate third-party tests, and capture the manufacturing instructions needed for the next build.
For broader material exploration, appearance models, packaging, and presentation work, see Product & industrial design.
B Mechanical design, engineering, and fabrication
07 services
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3D modeling and CAD design
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3D scanning
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3D printing
FDM for ABS, PLA, and PETG plastics, plus resin-based SLA.
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Laser cutting and marking
CO2, diode, and fiber.
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CNC milling
2D and 3D in wood, aluminum, copper, carbon fiber, and other materials.
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Robotics and animatronics
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Prop and model fabrication
C Traditional craftsmanship
02 services
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Traditional woodworking
Table saw, routers, bandsaw, joinery.
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Metalworking
Aluminum, brass, copper, and steel. Welding, brazing, bending, laser etching and marking, and plasma cutting done in-house.
D Alternative fabrication methods
12 services
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Leatherwork
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Wearables, costuming, and soft parts assembly
Electronics and textiles together.
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Silk screening
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Heat press
Heat transfer vinyl, sublimation, and direct-to-film transfers.
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Glasswork
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Vinyl cutting
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Foam cutting
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Vacuum forming
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Resin casting and silicone molds
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Sculpture
Clay and foam.
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Injection molding
Polyurethane resins, flexible and rigid, with color pigmentation.
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Parts finishing and painting
◫ Try the bench
Shop math, worked live.
Two of the calculations we reach for most before a cut. Offline, in the browser.
Board feet
Lumber
Cut yield
Kerf aware
05 / Yours to build on
Useful files. Useful evidence.
The handoff is scoped around what your team or supplier needs to do next.
- Design files: agreed native CAD with editable features where supported, STEP models, part and assembly drawings, dimensions, and material specifications.
- Product layout: enclosure geometry, internal arrangement, mounting points, openings, fastening, and service clearances.
- Build records: bill of materials, sourcing notes, finish specifications, assembly instructions, and manufacturing or inspection requirements.
- Test evidence: configurations, observations, measurements, limitations, failure findings, and prioritized improvements.
- Delivery: a demonstration of the agreed functions, acceptance review, and shipping arrangements for the prototype or samples.
Need the electronics and code developed alongside the mechanics? Explore electronics engineering and firmware & software.
Ready when you are
Bring the question.
Let’s build the next step.
An idea, a drawing, a stubborn problem, or a prototype that needs another set of eyes. Tell us where you are and what you need to learn.
Schedule a consultation