Design
Centre

OVERVIEW

Our Design Department follows a structured, multi-stage approach to creating tools, fabrication components, and machines, throughout the entire process. This approach begins with close collaboration between design engineers and manufacturing teams to understand the project requirements, constraints, and objectives. By integrating manufacturing considerations early in the design phase, we ensure that each part is optimised for the most suitable production method and simplifying the assembly process.

Throughout the design process, our Design Team works closely with the production team to ensure that the design is fully aligned with our manufacturing capabilities, optimising both feasibility and efficiency.

Conceptual Design & Feasibility Analysis

Conceptual Design is critical in transforming initial ideas into actionable plans. This phase begins with Brainstorming and Ideation, where a wide range of design concepts and solutions are generated. Using techniques like sketching, mind mapping, and group brainstorming sessions, the team explores various possibilities, encouraging creativity and innovation. The goal is to identify several potential directions before narrowing the focus.

Next, a Feasibility Analysis is conducted to evaluate the practicality of each concept. This involves assessing factors like technical feasibility, cost-effectiveness, and manufacturability to ensure that the ideas can be realistically implemented within the constraints of the project. A rough analysis is performed to check whether the concepts align with the client’s requirements and operational needs, helping to eliminate non-viable options early on.

Finally, the most promising concept is chosen through Concept Selection, based on the results of the feasibility analysis and the project’s specific goals. This selected concept is then presented to the client for approval before moving forward with further development. During this step, a preliminary design outline is created, and key design parameters—such as size, materials, and performance criteria—are established. This lays the foundation for more detailed design work in the subsequent phases, ensuring that the chosen concept is both innovative and achievable.

Detailed Design & Analysis

The Detailed Design phase takes the conceptual design to the next level, refining it into a fully developed and production-ready solution. This phase begins with Creating Detailed Drawings, where our design team develops precise CAD models and technical drawings. These drawings include all necessary dimensions, tolerances, material specifications, and assembly instructions, ensuring that every component is clearly defined for manufacturing.

Next, we perform thorough Engineering Analysis to validate the design. This step includes several types of analysis to ensure the product performs as expected under various conditions:

Stress Analysis

We use methods like Finite Element Analysis (FEA) to evaluate stress and strain on the components, ensuring they can withstand operational forces without failure.

Thermal Analysis

We analyze temperature distribution and thermal effects to ensure that the design can handle temperature fluctuations and dissipate heat effectively.

Dynamic Analysis

This involves evaluating vibrations, forces, and dynamic responses to ensure that the design performs optimally under motion or variable forces.

Fluid Dynamics Analysis

For systems involving fluid flow, we perform Computational Fluid Dynamics (CFD)to predict how fluids interact with the components, optimizing flow efficiency and system performance.

Finally, we move to Prototype Development, where a physical prototype or virtual simulation model is built to test the design in real-world conditions. This step allows us to validate the design and identify any potential issues early in the process. Testing the prototype provides invaluable insights, which can be used to further refine and perfect the design before moving on to production.

Software Tools and Hardware Resources

To ensure precision and efficiency throughout the design and manufacturing process, we rely on a suite of advanced software tools and cutting-edge hardware resources. Our CAD Software includes powerful platforms like Unigraphics, AutoCAD & Siemens NX which allows us to create detailed 3D models, technical drawings, and accurate representations of parts and assemblies. These tools enable our team to visualise and refine designs before moving to the next stages of production.

For simulation and analysis, we use industry-leading tools such as ANSYS and COMSOL. These simulation platforms help us perform stress analysis, thermal analysis, and fluid dynamics simulations, ensuring that each design can withstand real-world conditions and operate efficiently. By leveraging these tools, we can predict performance, identify potential weaknesses, and optimize the design before physical prototyping.

To effectively track and manage the progress of each project, we utilize advanced project management tools such as Microsoft Project. These tools help track milestones, allocate resources, and ensure that tasks are completed on time, facilitating collaboration across teams and keeping projects on schedule.

In terms of hardware resources, we utilize our vast in-house capabilities by leveraging our existing infrastructure such as our Tool Room & Fabrication Facility to build & refine Prototypes. These tools allow us to quickly turn digital designs into physical models, which can then be tested and evaluated. For testing equipment, we use specialized tools to measure mechanical properties, including load testers, thermal chambers, and vibration analysis equipment. We use Universal Testing Machines (UTM) for conducting load testing to ensure the strength and durability of our products. These resources allow us to thoroughly test the prototypes under real-world conditions, ensuring that every component performs as expected before final production. Together, our software and hardware resources enable us to maintain high standards of quality, efficiency, and precision throughout the entire development process.

Systematic Risk Assessment through DFMEA

At our facility, we implement Design Failure Mode and Effects Analysis (DFMEA) as an integral part of our product development process. DFMEA is a structured, systematic method used to identify potential failure modes in the design phase of a product and evaluate their impact on product performance, safety, and reliability. Through this analysis, our cross-functional team—including engineers, designers, and quality assurance experts—collaborates to assess the likelihood and severity of each failure mode and its potential consequences. By systematically analyzing every component and process, we prioritize risks based on their potential impact, enabling us to proactively implement corrective actions, such as design modifications or process improvements, before production begins. This approach not only helps mitigate the likelihood of failures but also ensures that we meet regulatory standards and exceed customer expectations for product quality and safety. Ultimately, DFMEA strengthens our ability to deliver reliable, high-performance machines & equipment while minimising costly delays and rework during the manufacturing stage.

Post-production Support

After the product has been delivered, the Design Department continues to provide post-production support to ensure the product’s long-term success. This support includes maintenance, and any necessary modifications based on real-world usage. Whether it’s performing routine maintenance, making design adjustments, or offering technical assistance, ongoing support ensures that the product remains reliable, functional, and efficient over time. By staying engaged even after delivery, we help clients maximize the lifespan and performance of the product, ensuring that it continues to meet operational requirements and deliver value in the long run.

“Designing Tools to Make More Tools, the cool part about designing tools for fabrication and machine building is that they often create tools that will, in turn, make other tools! For example, a specially designed fixture can be used to create precise components for an entirely new machine.”

Knowledge
Nuggets

“Where Engineering Meets Art, Designing tools and machines requires a mix of technical knowledge and artistic skill. The ability to balance form with function is what turns a basic idea into a groundbreaking design that performs well and looks good doing it.”