Product Development
Mechanical & Structural Design
The internal architecture that makes a product assemble reliably, seal properly and survive its environment.
Overview
Mechanical design is where most schedule risk hides. The board is designed before the enclosure, the enclosure is designed before the connector is chosen, and the first prototype reveals that the battery, the speaker and the antenna all want the same volume.
We design the internal architecture as a system: board mounting and standoffs, battery retention, sealing strategy, connector access, button feel and the assembly sequence. Parts are modeled in 3D with tolerances that reflect the real process — injection molding, die casting or sheet metal.
For products that need ingress protection or drop resistance, we define the seal geometry, check the compression on the gasket, and specify the test method. Where required, we produce tolerance stack-up analysis for critical interfaces so that parts fit at the extremes of their tolerance bands, not just at nominal.
Capabilities
What this covers
Internal architecture
Board mounting, battery volume, connector access and assembly sequence designed together, not in sequence.
Part and assembly design
3D part models, snap fits, screw bosses, gaskets and cable routing with manufacturing tolerances applied.
Sealing and durability
Gasket geometry, compression analysis and test methods for IP-rated and drop-tested products.
Tolerance stack-up
Critical interfaces analysed at tolerance extremes, so parts assemble in production rather than only on screen.
Specification
Technical specifications
| Typical duration | 4 – 8 weeks depending on part count |
|---|---|
| You receive | 3D part and assembly models, 2D drawings, BOM, assembly instructions |
| Deliverable formats | STEP, STP, DXF, PDF drawings |
| Processes covered | Injection molding, die casting, sheet metal, CNC, silicone |
Applications
Where it is used
- Smart lock bodies and escutcheons
- Sensor housings with IP sealing
- Gateways and control boxes
- Wearable and handheld devices
- Mounting brackets and enclosures
Related
Continue exploring
Tell us what you are building.
Send us the requirement, the target market and the volume you have in mind. We will come back with a technical response and an indicative quotation — usually within one business day.