Mechanical Design Engineering
Enclosure and mechanical design that is manufacturable, integrates with the electronics inside it, and still feels good in the hand.
Mechanical design decides whether a product can be assembled, whether it survives being dropped, and whether it feels like a finished object. We work from concept and 3D CAD through material selection and structural analysis to a design that is ready for its chosen manufacturing process.
What this includes
- SolidWorks 3D CAD modelling, concept development and rendering
- Enclosure design co-developed with the electronics
- Design for injection moulding, 3D printing and fabrication
- Material selection and surface finishing
- Structural analysis and drop testing
- Tolerance analysis and assembly sequence design
Enclosure design that fits the electronics
Enclosures designed in isolation from the boards they house cause late, expensive problems: connectors that do not line up, antennas detuned by nearby metal, thermal paths that do not exist. Our mechanical and electronics engineers work on the same projects, so the enclosure and the PCB are designed against each other from the start rather than reconciled at the end.
Design for manufacture across processes
We design for the process a product will actually use, whether that is 3D printing for early volumes, injection moulding at scale, or metal fabrication for industrial housings. That means draft angles, wall thicknesses, tooling costs and assembly sequence are considered while the design is still cheap to change, and it means we will tell you when moulding cannot yet be justified by your volumes.
Materials, structure and validation
Material selection balances cost, durability, finish, regulatory requirements and environmental exposure. Where a part carries load or has to survive a drop, we use structural analysis and physical testing to confirm it does, rather than assuming.
Common questions
Can you design an enclosure around our existing PCB?
Yes, and it is a common request. We will flag early if the board layout makes the enclosure harder or more expensive than it needs to be, so you can decide whether a small PCB change is worth it before tooling money is committed.
When does injection moulding make sense over 3D printing?
It depends on volume, part geometry and finish requirements. Tooling is a significant up-front cost that pays back over enough units, so we model both routes against your forecast volumes and tell you where the crossover actually falls for your product.
Ready to bring your idea to life?
We provide affordable engineering services for professional prototypes and short-run production.
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