AI-Powered Mechanical Design & Engineering Services
From napkin sketch to market-ready product.
We translate your vision into precise, manufacturable designs using advanced CAD modeling,
simulation, and rapid prototyping.
Your Strategic Partner in Mechanical Innovation
We're not just a service provider; we're an extension of your team. We combine deep engineering expertise with AI-driven insights to deliver designs that are not only innovative but also cost-effective and ready for manufacturing.
AI-Enhanced Design
We leverage generative design and AI-powered simulations to explore thousands of design possibilities, optimizing for performance, weight, and material usage far beyond human capacity.
Manufacturability First
Our Design for Manufacturability (DFM) and Assembly (DFA) analysis is embedded in our process, ensuring your product is not just brilliant on screen but also efficient to produce at scale.
Accelerated Prototyping
With in-house expertise in 3D printing and rapid prototyping techniques, we quickly turn digital models into physical, testable parts, dramatically shortening your development cycle.
Cross-Functional Experts
Our team isn't siloed. Mechanical engineers collaborate with materials scientists, electronics engineers, and software developers to deliver holistic, integrated product solutions.
Full IP Protection
Your intellectual property is paramount. We operate under strict NDAs and secure protocols, ensuring your groundbreaking ideas remain yours. You get full IP rights upon project completion.
End-to-End Lifecycle
From initial concept and feasibility studies to detailed CAD modeling, FEA analysis, prototyping, and production-ready documentation, we support you at every stage of the product lifecycle.
Comprehensive Mechanical Design & Engineering Services
Our services cover the entire spectrum of mechanical product development. We tailor our approach to your specific needs, whether you're a startup with a new idea or an enterprise optimizing an existing product line.
Conceptual Design & Industrial Design
We transform your initial ideas into tangible concepts, focusing on functionality, ergonomics, and aesthetics to create a strong foundation for your product.
- Ideation and brainstorming workshops to refine your vision.
- Development of multiple design concepts with sketches and renderings.
- User-centric design approach to ensure market appeal and usability.
3D CAD Modeling Services
Our core offering involves creating precise, detailed, and manufacturable 3D models using industry-leading software like SolidWorks, CATIA, and Autodesk Inventor.
- Parametric modeling for easy design modifications and iterations.
- Complex surface modeling for aesthetic and aerodynamic components.
- Assembly modeling with interference and clearance checks.
2D Technical Drawings & Drafting (GD&T)
We produce comprehensive 2D manufacturing drawings complete with Geometric Dimensioning and Tolerancing (GD&T) to ensure parts are fabricated exactly to spec.
- Creation of detailed part and assembly drawings.
- Application of ASME Y14.5 standards for clarity and precision.
- Bill of Materials (BOM) generation and management.
Reverse Engineering Services
We can accurately recreate digital models from existing physical parts, enabling you to improve, remanufacture, or analyze competitor products.
- 3D scanning of physical objects to capture precise geometry.
- Conversion of scan data into fully parametric CAD models.
- Material analysis and performance benchmarking of the original part.
Finite Element Analysis (FEA)
We digitally test your designs under real-world conditions to predict performance, identify weak points, and optimize for strength and durability before a single part is made.
- Structural analysis (static, dynamic, fatigue) to assess integrity.
- Thermal analysis to manage heat dissipation and performance.
- Vibration analysis to understand and mitigate resonance issues.
Computational Fluid Dynamics (CFD)
Our CFD simulations analyze fluid flow and thermal performance, crucial for optimizing everything from aerodynamics to cooling systems and hydraulic performance.
- Aerodynamic and hydrodynamic efficiency analysis.
- Electronics cooling and thermal management simulation.
- Flow analysis for valves, pumps, and internal passages.
Design for Manufacturability (DFM) & Assembly (DFA)
We analyze your design to ensure it can be manufactured and assembled efficiently and cost-effectively, minimizing production issues down the line.
- Part simplification and feature optimization for specific manufacturing processes.
- Tolerance analysis to balance cost and performance.
- Assembly sequence planning and fixture design recommendations.
AI-Powered Generative Design
Using AI algorithms, we define your design goals and constraints, then let the system generate and evolve hundreds of optimized design options for you to choose from.
- Topology optimization for maximum strength-to-weight ratio.
- Exploration of novel, high-performance geometries.
- Ideal for lightweighting applications in aerospace, automotive, and robotics.
Rapid Prototyping & 3D Printing
Quickly create physical prototypes for form, fit, and function testing. We utilize various technologies like FDM, SLA, and SLS to match your material and resolution needs.
- Fast turnaround for design verification and user feedback.
- Creation of functional prototypes with engineering-grade materials.
- Small-batch production for pilot runs and market testing.
CNC Machining Prototyping
For prototypes requiring high precision and production-grade materials, we provide CNC machining services for both metal and plastic components.
- 3-axis and 5-axis CNC milling and turning.
- High-tolerance parts for functional and mechanical testing.
- Wide range of material options, including aluminum, steel, and titanium.
Sheet Metal Design & Fabrication
We design and prepare documentation for sheet metal components, including enclosures, brackets, and chassis, optimized for fabrication processes like bending and stamping.
- Flat pattern generation and bend allowance calculations.
- Design for laser cutting, punching, and forming processes.
- Weldment design and structural frame analysis.
Production Sourcing & Vendor Liaison
Leverage our network and expertise to find the right manufacturing partner. We create detailed technical data packages and act as your liaison to ensure quality control.
- Preparation of comprehensive RFQ packages for vendors.
- Supplier evaluation and selection assistance.
- First article inspection (FAI) and quality assurance support.
Proven Success in Mechanical Engineering
We deliver tangible results. Explore how we've helped businesses across various industries overcome complex design challenges and launch successful products.
Redesigning a Robotic Gripper for a Manufacturing Giant
Industry: Industrial Automation & Robotics
Client Overview: A leading provider of automated manufacturing solutions needed to develop a next-generation robotic gripper. Their existing model was heavy, expensive to produce, and had limited payload capacity, creating a bottleneck in their clients' assembly lines.
"The team at Developers.dev didn't just give us a new design; they gave us a competitive advantage. Their use of generative design and DFM analysis was a game-changer for our production costs and performance."
Key Challenges:
- Reduce component weight by at least 30% without sacrificing strength.
- Simplify the assembly from 25+ parts to under 10.
- Improve gripping force and precision for delicate components.
- Decrease the per-unit manufacturing cost by 20%.
Our Solution:
- Utilized AI-powered generative design to create a lightweight, organically-shaped main body.
- Conducted extensive FEA simulations to validate the new design's structural integrity under maximum load.
- Redesigned the actuator mechanism, consolidating multiple parts into a single, complex 3D-printed component.
- Provided a complete DFM analysis, shifting from costly CNC milling to a combination of metal 3D printing and injection molding.
Developing a Rugged, Waterproof Enclosure for an IoT Device
Industry: Consumer Electronics & IoT
Client Overview: A well-funded startup was developing an outdoor environmental sensor. They had the electronics figured out but needed a compact, durable, and completely waterproof enclosure that could be mass-produced affordably and withstand harsh weather conditions for years.
"Their expertise in injection molding and IP rating certification was invaluable. We went from a clunky prototype to a sleek, production-ready design in record time. We passed IP67 testing on the first attempt."
Key Challenges:
- Achieve a certified IP67 waterproof and dustproof rating.
- Design for high-volume injection molding with minimal post-processing.
- Ensure thermal management for the internal electronics.
- Create a design that was both functional and aesthetically pleasing for the consumer market.
Our Solution:
- Designed a two-part enclosure with a custom gasket and interlocking features for a robust seal.
- Performed mold flow analysis to optimize gate locations, prevent defects, and reduce cycle times.
- Conducted CFD simulations to ensure passive cooling of the internal PCB through strategically placed heat fins.
- Created multiple 3D printed prototypes for fitment checks and user testing before committing to expensive tooling.
Reverse Engineering and Improving a Legacy Automotive Part
Industry: Automotive Aftermarket
Client Overview: A supplier of aftermarket automotive parts needed to reproduce a discontinued transmission component for a classic car model. Original drawings were unavailable, and they wanted to improve the part's known failure points while maintaining perfect fitment.
"The accuracy of their reverse engineering was incredible. They not only replicated the part perfectly but their FEA analysis identified and fixed the original design flaw. We now have a superior product."
Key Challenges:
- Create a production-ready CAD model from a worn, physical sample with no documentation.
- Identify and rectify the original design's common stress fracture point.
- Select a modern, more durable alloy that was still compatible with the existing system.
- Ensure 100% dimensional accuracy for drop-in replacement.
Our Solution:
- Utilized a high-resolution 3D laser scanner to capture the part's complex geometry.
- Converted the scan data into a fully parametric SolidWorks model, allowing for precise modifications.
- Ran FEA simulations on the new model, which confirmed the high-stress area. We then added material and fillets to reinforce it.
- Worked with metallurgists to specify a superior forged steel alloy and created a complete technical drawing package for the manufacturer.
Our Structured Design & Development Process
We follow a phased approach to ensure clarity, control, and successful outcomes, moving from broad concepts to detailed, validated designs.
Phase 1: Discovery & Feasibility
We start by deeply understanding your goals, requirements, and constraints. This phase is about aligning on the vision and defining the project's success criteria.
Phase 2: Concept & Design
Our creative and engineering teams collaborate to develop initial concepts, create 3D models, and explore different approaches to solving the core design challenges.
Phase 3: Analysis & Optimization
Here, we put the designs to the test digitally. Using FEA and CFD, we simulate real-world performance, identify areas for improvement, and optimize the design for manufacturability.
Phase 4: Prototyping & Validation
We create physical prototypes for you to test and validate. This crucial feedback loop allows us to make final adjustments before committing to mass production.
Phase 5: Documentation & Handover
The final phase involves creating a complete technical data package, including detailed 2D drawings, BOMs, and manufacturing specifications for a seamless transition to production.
Our Engineering Toolkit
We utilize a comprehensive suite of industry-standard and cutting-edge software to deliver precision, efficiency, and innovation in every project.
What Our Clients Say
Our success is measured by the success of our clients. Here’s what they have to say about partnering with us.
"The level of detail in their 2D drawings and GD&T application saved us countless hours and thousands of dollars in manufacturing errors. Truly professional from start to finish."
"We came to them with a complex thermal management problem for our new device. Their CFD analysis was spot on and led to a design that works flawlessly. Highly recommended."
"The speed at which they delivered functional 3D printed prototypes was incredible. It allowed us to get user feedback and iterate on our design much faster than we thought possible."
Frequently Asked Questions
Have questions? We have answers. Here are some common inquiries about our mechanical design services.
Our team is proficient in a wide range of industry-leading CAD software. Our primary platforms are SolidWorks, Autodesk Inventor, and CATIA. We can also work with files from other systems like Siemens NX and Creo. We select the best tool for your project's specific needs, considering factors like industry standards, complexity, and required analyses.
Your IP is your most valuable asset, and we treat it with the utmost respect and security. We start every engagement with a mutual Non-Disclosure Agreement (NDA). All project data is stored on secure, encrypted servers with restricted access. Upon final payment, all intellectual property, including all CAD files, drawings, and analysis reports, is fully transferred to you.
Absolutely. While we offer end-to-end services, we understand that you may only need assistance with a specific phase. We frequently engage with clients for standalone services such as FEA simulation on an existing design, reverse engineering a single component, or creating manufacturing drawings from a completed 3D model. Our engagement models are flexible to meet your needs.
Project timelines vary greatly depending on complexity. A simple component design might take a week, while a complex multi-part assembly with extensive analysis could take several months. After our initial discovery phase, we will provide you with a detailed project plan that includes key milestones and estimated timelines for each phase, ensuring transparency throughout the process.
Design for Manufacturability (DFM) is a core principle of our workflow, not an afterthought. From the early concept stages, our engineers consider the intended manufacturing processes (e.g., injection molding, CNC machining, sheet metal fabrication). We perform DFM analysis throughout the project, optimizing geometries, tolerances, and material selections to reduce costs and ensure a smooth transition to production.
Ready to Build the Future?
Let's turn your innovative idea into a market-leading product. Schedule a free, no-obligation consultation with our engineering experts to discuss your project and discover how we can accelerate your path to production.