PRODUCT DESIGN

Product design is the process of creating a product from the idea phase all the way to the prototype phase and ultimately to manufacturing.

A typical product design process starts out with an idea, followed by a design concept, 3D model in a CAD software, to detail drawings for manufacturing. In most cases, a prototype is made base on the final model before manufacturing to avoid and rule out any errors or flaws in the design.

Most of our customers come to us with an idea or a rough sketch. Based on that, we build a detailed design concept and share it back to our customers for approval. A typical design concept takes into consideration the overall aesthetic language of the design, the specifications for any mechanisms, what materials will be used and the necessary manufacturing process, and a rough idea on the cost based on experience.

Once the customer approves a design concept, we start modeling the design in a CAD software. During the 3D modeling phase, some design changes may be made based on the customers’ feedback. When designing each of the components, we take into consideration how that part will be manufactured. If the design is an assembly, we make sure that it can be assembled later on. After the modeling has been completed, we send it to the customer again for final approval. Once approved, we move on to creating the applicable drawings for all the components in the design. Every design will require a unique set of drawings depending on the type of manufacturing process chosen for each of the components.

Depending on the type of design, many customers also choose to use our in-house prototyping service before sending it for production. Prototyping can help in getting a hands-on feel of the design. We use an SLA based 3D printer to print our plastic parts. In addition, we can pick the most suitable material for the parts from a wide catalogue of materials. If needed, we also procure off-the-shelf components from suppliers to complete the prototype.

For off-the-shelf components, using them in a design can be a good thing if they can be properly integrated as they help in saving time and reducing the manufacturing cost. However, it is very important to use off-the-shelf components early on in the design concept that can be procured in the quantity needed, while maintaining the budget of the design. Over the years, many of our customers bring us partially completed designs that are based on off-the-shelf components that cannot be procured at a reasonable price for the quantity needed. For such projects, we try to fix the design by using the existing parts as much as possible, and modifying only the necessary components to keep the cost low.

Our product design solution combines all of our mechanical design services like sheet metal and weldments, pipe routing, fabrication and machining, and even Scan-to-CAD solutions when needed. For more information on the individual solutions please use the links below.

We believe that all ideas have the potential to become great if implemented properly. We strive to take these ideas to a physical product, and keep the costs reasonable by using our experience to design in a smarter way.

For more information, please read our orthotic prototype case study to see how an idea was taken to a prototype. Contact us today to discuss your next project and how we can help bring it to life through smart designing to save you time and keep the cost of production low.

2D TO 3D CAD CONVERSION

Many companies have 2D drawings of equipment and parts that are in digital and hard-copy format and are wanting to convert them to 3D models for modifying and optimizing their designs. However, due to limited resources, many companies are never able to convert their 2D drawings to 3D models, and are forced to use older methods when modifications and optimizations are needed for their parts and equipment.

Having 3D models of parts and equipment allows for rapid modifications which translate into real cost savings for companies. 3D models allow companies to take advantage of new technologies like 3D printing to save time and money during the prototype stage. 3D models are also required when machining parts from 2D drawings as most CNC machines and shops use STEP files to generate their CNC G-codes.

Our expertise with various CAD software and our ability to read and understand 2D drawings of all types from most of the major industries lets us assist our customers in converting their 2D drawings to 3D models in a timely and cost-effective way.

Feel free to contact us if you need 2D to 3D CAD conversion services by using the link below.

SHEETMETAL AND WELDMENTS

Sheetmetal is a fundamental form of metalworking used in countless everyday objects as well as major industries like automobile, aerospace, construction and even medical. Sheet metal comes in various thicknesses and can be bent and cut into a variety of simple and complex shapes. Designing sheet metal parts is a complex process, as the designer has to take into account the material properties of different metals in conjunction with their thicknesses (gauges), and how the metal will deform when bent or cut as different metals have different limitations and allowances.

Weldments, like sheet metal, is also an integral part of metalworking and used for fabricating metal parts and structures by joining two metal parts through the process known as welding. It is also important for a designer to know where and how weldments will be made and the proper equipment needed to maintain cost-efficiency.

Knowledge in making drawings for sheet metal and weldments is also important as they are needed once a product or equipment has been designed, analyzed and approved for production. Sheet metal drawings are unique as they require flat patterns to be shown and bend deductions to be called out. For weldment drawings, weld symbols need to be shown and cut parameters for the weldments defined properly. Creating sheet metal and weldment drawings takes a considerable experience and knowledge in these fields.

Our designers and engineers have a combined understanding in sheet metal and weldments of over two decades. This experience allows us to save time and cost when designing sheet metal and weldments for parts and structures. Feel free to contact us if you have a design that requires knowledge and experience in sheet metal or weldments by using the link below.

PIPE ROUTING AND FABRICATION

In the industrial sector especially in the Oil & Gas, Food and MEP sectors, pipe-routing is an essential part of the industry. When process plants in these sectors undergo expansion or are repurposed for a different function, the piping also has to be increased or adapted at the same time. Most companies do not have an in-house design and engineering team to handle these types of workloads. Additionally, designing new or modifying existing piping can be time-consuming and costly if the piping is in as-built conditions.

Together with pipe-routing, knowledge and experience in fabrication and machining is also important because they dictate how the piping will be manufactured and installed on the site. Without the proper experience in fabrication and machining practices, companies can suffer huge costs when piping cannot be installed on-site as per the design. In addition, our experience in these three areas can allow companies to design a more efficient and cost-effective system.

For companies needing pipe-routing services, the combined experience of more than 20 years of our design and engineering team can provide the best solution in the industry. We can also augment our workflow with portable and aerial 3D Scanners to document as-built conditions before starting a project to avoid any unwanted costs down the line. Feel free to contact us if you need our knowledge and experience in pipe routing and fabrication by using the link below.

PHOTO-REALISTIC RENDERS AND HIGH-RESOLUTION VIEWS

Once a product has been designed, photo-realistic renders are needed to showcase and advertise it, while high-resolution views are needed for manuals and specifications. We can provide renders and high-resolution views in many styles and resolutions as required by the customer and is part of our mechanical solution that we provide to our customers.

EXPLODE / COLLAPSE ANIMATIONS AND VIEWS

Explode / Collapse animations and views are useful when the inner workings of a product have to be shown. Exploded views are also used in manuals for assembly instructions and in drawings for patents. Our team has the expertise for creating immersive explode/collapse animations and views for our customers in many styles including in photo-realistic detail.