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Static Component Design & Manufacturing

We develop and refine components to meet fit, form, and functional performance requirements within larger assemblies or experimental rigs. Work can start from a CAD model, drawings, sketches, an existing part, or simply a conversation.

Capabilities include:

  • One-off components designed from concept

  • Reverse-engineering of existing hardware

  • Parametric CAD modeling and manufacturability evaluation using SolidWorks

  • Prototype production via in-house CNC machining and Fusion CAM, or coordinated sourcing

Components are engineered to integrate efficiently into assemblies and support iterative testing and refinement.​​​​​

Dynamic Modeling & System Development

For multi-component and multi-domain systems, we translate requirements into quantitative, physics-based models that capture relevant mechanical, electrical, thermal, and control interactions.​

Key elements include:

  • System-level mathematical modeling and simulation using Python and Modelica, with the ability to migrate to MATLAB/Simulink if the client prefers

  • Parameter studies, performance trade-offs, and sensitivity analysis

  • Data-informed guidance for architecture decisions, component sizing, and control strategies​​

Models provide a rigorous, testable foundation for development and allow informed design decisions before hardware is built.

Integrated Prototyping

This is where system modeling and component design converge. We construct functional prototypes to validate real-world system behavior using: 

  • Insights from multi-domain mathematical and physics-based models to guide component and system-level design

  • In-house machining, sourced hardware, and hands-on assembly to bring model-driven designs into physical form

  • Instrumented testing and iterative refinement to ensure both component-level and system-level behavior match analytical predictions.

  • Direct continuity from models to prototype, enabling rapid validation and high-confidence results

This approach ensures prototypes are robust, functional, and built on a foundation of system-level, energy-aware analysis, rather than being derived solely from dimensional or kinematic constraints.

Scope Disclaimer

All services are limited to R&D and product-development and are not offered for regulated or safety-critical engineering work. Projects - or portions of projects - that fall under this category may be undertaken if and only if the client retains a licensed professional engineer, competent in the relevant domain for any regulated or potentially hazardous aspects, with final responsibility remaining with the licensed professional.

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Note: Experimental, prototype, or development systems (e.g., one-off vehicles, test rigs, or other non-commercial systems and/or components) are generally considered non-regulated for these purposes, though clients are responsible for understanding any applicable rules or certifications required for future commercial or public use.

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