Mechanical design and CAD — enclosures, mechanisms, DFM-ready outputs.
CAD, enclosure and mechanism design, DFM support and prototype-ready outputs. Pragmatic robotic/mechatronic design included.
What this service is
Enclosures & housings
Designed around your PCB and component stack — not the other way around. We build for assembly, not just aesthetics.
Brackets, fixtures & mechanisms
Structural and functional hardware — mounting, articulation, retention. Toleranced for the manufacturing process you're actually using.
Mechatronic / robotic mechanical design
Pragmatic and prototype-focused. We scope to what the product needs to prove — not research-grade precision for its own sake.
DFM — design for manufacture
DFM built into the design process, not bolted on at the end. Fewer revision cycles, fewer surprises when parts come back.
— Typical outputs
Important boundary
This is not civil engineering. Structural analysis for buildings, bridges, or load-bearing civil infrastructure sits outside our scope.
Who it's for
Tap any card to flip it — front shows the fit, back shows why.
Problems we solve
Click a problem to see the root cause and what we do about it.
Our prototype doesn't fit together reliably.
We need an enclosure that protects electronics and is manufacturable.
We need mechanism design that can be built and iterated.
We need CAD cleaned up and made production-ready.
We need DFM improvements to reduce cost and assembly time.
Select a problem on the left
What you receive
Click any tile to see what's in it and when it applies.
CAD models
Native + STEP
Native format for your CAD tool plus universal STEP export — ready for your manufacturer or next engineer.
Drawings
Where required
2D engineering drawings with GD&T, tolerances, and surface finish callouts — wherever your supplier needs them.
Assembly guidance
Notes + instructions
Step-by-step assembly notes, torque specs, and sequence — so the build can be handed to someone who wasn't in the room.
Tolerance & fit checks
Stack-up analysis
Tolerance stack-up reviewed at assembly level — before parts are made, not after they come back wrong.
Prototype build pack
Fabrication + assembly
What to order, from where, in what order to build — a single document your team can follow without chasing us.
DFM recommendations
Redesign outputs
Prioritised list of design changes — ordered by cost/assembly impact — with updated geometry where agreed.
If the work includes electronics integration, we'll coordinate with PCB and enclosure constraints — deliverables scoped to match.
How we engage
Three paths depending on how defined your scope is. Click an option to see outputs and timing.
Quick CAD / DFM audit
Paid sprint style
Best when
You have existing CAD and want a clear, prioritised plan to improve it — without committing to a full redesign first.
Outputs
Prioritised fix list — ordered by cost / assembly impact
Redesign approach for top issues
Estimate range for implementation (where possible)
Fixed scope CAD pack
Defined deliverable set
Best when
Deliverables are already clear — e.g. enclosure redesign, bracket set, mechanism. Scope agreed upfront, delivered to spec.
Outputs
Full CAD model (native + STEP)
Engineering drawings where needed
Build pack — what to fab, how to assemble
Milestone-based mechanical design
Iterative delivery
Best when
Constraints evolve and iteration is expected — design is staged across milestones with review and sign-off at each gate.
Outputs
Staged design milestones with review gates
Evolving CAD updated each stage
Risk log and open items tracked throughout
Minimum engagement
Contact us for current availability and minimum scope.
Tools & stack
Mainstream CAD tools, exchangeable formats. Toolchain confirmed during discovery. Click a category to see tools — hover a tool for context.
Fusion 360
Default — parametric, cloud-collaborative, DFM features built in
FreeCAD
Open-source alternative where client toolchain requires it
STEP / STP
Universal — every supplier and downstream engineer can open it
DXF / DWG
2D drawings and laser / waterjet cut profiles
STL / 3MF
3D print-ready exports for rapid prototype runs
FEA (Fusion)
Static stress and deflection — enclosures, brackets, fixtures
Tolerance analysis
Stack-up review before committing to manufactured parts
Engineering drawings
GD&T annotations, tolerances, and finish callouts
BOM
Bill of materials — part numbers, quantities, supplier references
Assembly instructions
Sequence, torque specs, and build notes
Toolchain and file formats confirmed during discovery — always matched to your supplier and downstream workflow.
Relevant work
Published with permission — many can be anonymised. Click a row to see the before and after.
Before
Prototype enclosure with 14 design issues flagged by manufacturer — tooling cost estimate was 40% over budget.
After
Wall thicknesses corrected, draft angles added, snap-fit redesigned. Tooling quote reduced significantly after redesign.
14
issues resolved before tooling
Before
Wearable device needed enclosure designed around an existing PCB — with a folding mechanism and two-part housing.
After
Full CAD pack delivered: enclosure, folding mechanism, tolerance study, and build instructions ready for 3D print run.
V1
prototype built from pack
See all work
Full case study library across all service areas
How we keep quality high
Quality you can see, not just trust. Hover any row to see what makes it visible.
Pillar
When
What's visible
Clear requirements & acceptance criteria
Fit, function, constraintsRequirements brief agreed and signed off before any CAD begins. Fit, function, and manufacturing constraints all captured — so rework is a choice, not a surprise.
Design review and risk tracking
Interference, tolerances, assemblyAssembly interference checks, tolerance stack-up review, and a shared risk register — updated at each stage, visible to you throughout.
Prototype validation notes
Where applicableTest notes documenting what was validated, what wasn't, and known edge cases — included in the handover so the next engineer knows what the prototype proved.
Build-ready handover pack
CAD, drawings, BOM, instructionsSTEP files, engineering drawings, BOM, and assembly instructions delivered together — structured for a manufacturer or next engineer who wasn't in the room.
See the full process
How we scope, build, review, and hand over — end to end
Frequently Asked Questions
Everything you need to know before starting an AI features project.
Do you do robotic mechanism design?
Can you design for manufacture (DFM)?
Can you work with our manufacturer?
Is this civil engineering?
Still have questions?
Book a free discovery call→Let's build something
that actually ships.
Two ways in — a scoped estimate or a quick discovery call. Pick whichever fits where you are right now.
Get a Project Estimate
Tell us what you're building — we'll scope it and respond within 1 business day.
Book a Discovery Call
20 minutes, no obligation. We'll tell you honestly if we're the right fit.