At this stage all components of the design whether designed in house or bought off the shelf will be modelled in the 3d CAD software meticulously. This allows us to create a precision virtual assembly of the complete project and so detect areas of mechanical conflict with other components or assembly tools. Often we can detect assembly problems that we may not have detected until the pre-production run occurs. Part of our capability is to design assembly jigs and fixtures for assembly.

After the first Engineering Model is defined, Finite Element Stress Analysis is carried out to check for undetected early failure modes that could occur within the defined design and usage envelope. If high stress conditions are detected, then the product design is modified to manage out these high stress condition by design.

In addition dimensional tolerance budgeting is carried out to reduce the risk of an assembly not fitting together when component integration occurs. Tolerancing is a balance between parts integrating and the additional cost of higher tolerancing.

The product will be monitored constantly for Design for Manufacturing and the design will reflect the final method of production using our expertise in both production and manufacturing, if a component is to be injection moulded in mass production, then injection casting drafts will be designed into the product. This is not a phase, it is an integral part of design.

Engineering will produce 3d data for CNC machining purposes, manufacturing documentation and fully dimensioned 2d orthographic drawings for inspection and design file submission to regulatory bodies if required.

There will be a design review and approval by the client before Models and Prototypes are produced.