Case Studies
Real-world examples of how we help clients bring products from concept to reality
Consumer Gadget Startup
Challenge
A hardware startup needed to transform their concept sketch into a manufacturable product for crowdfunding.
Approach
We provided full CAD modeling, DFM consulting, and rapid prototyping services. Multiple iterations refined the design for injection molding.
Deliverables
Production-ready CAD files, technical drawings, 5 functional prototypes, supplier RFQ package
Outcome
Successfully launched on Kickstarter with 300% funding. Product now in mass production.
Medical Device Component
Challenge
A medical device company required a custom enclosure that met strict regulatory requirements and tight tolerances.
Approach
Conducted thorough DFM analysis, materials selection for biocompatibility, and tolerance stack-up studies. Delivered SLA prototypes for testing.
Deliverables
FDA-compliant design documentation, biocompatible material specifications, 10 test prototypes
Outcome
Component passed all regulatory testing on first submission. Now in clinical trials.
Industrial Tool Redesign
Challenge
An existing tool needed ergonomic improvements and cost reduction for higher-volume production.
Approach
Reverse-engineered the existing design, conducted user testing, and optimized for manufacturing with fewer parts and simpler assembly.
Deliverables
Redesigned CAD models, ergonomic analysis report, cost comparison, 3 prototype iterations
Outcome
35% cost reduction per unit, improved user satisfaction scores, and faster assembly time.
IoT Sensor Housing
Challenge
A tech startup needed weatherproof housings for outdoor IoT sensors with specific mounting requirements.
Approach
Designed IP67-rated enclosures with integrated mounting systems. Prototyped with SLA for fit testing, then produced 50 units via CNC machining.
Deliverables
Weatherproof housing design, gasket specifications, mounting hardware, 50-unit production run
Outcome
Sensors deployed successfully in field testing. Client ordered additional 200 units for pilot program.
Custom Packaging Solution
Challenge
A boutique brand needed premium packaging that protected delicate products while maintaining brand aesthetics.
Approach
Designed custom inserts and structural packaging using sustainable materials. Prototyped with 3D printing and cardboard mockups.
Deliverables
Packaging design files, die-cut templates, material specifications, 100-unit small batch
Outcome
Packaging reduced damage rates by 80% and received positive customer feedback on unboxing experience.
Autonomous Robotics Platform
Challenge
A robotics startup needed a modular chassis design for their autonomous delivery robot that could accommodate different payload configurations.
Approach
Developed a parametric CAD system allowing quick reconfiguration. Conducted FEA analysis for structural integrity and created multiple prototypes using SLS 3D printing for field testing.
Deliverables
Modular CAD assembly, FEA reports, 8 functional prototypes, assembly instructions, BOM with supplier recommendations
Outcome
Platform successfully tested in 3 cities. Design flexibility reduced time-to-market for new variants by 60%.
Aerospace Drone Component
Challenge
An aerospace company required lightweight, high-strength mounting brackets for commercial drone systems with strict weight and vibration requirements.
Approach
Utilized topology optimization and generative design techniques. Selected aerospace-grade aluminum alloy and validated designs through vibration testing and thermal analysis.
Deliverables
Optimized CAD models, material certifications, vibration test reports, 15 CNC-machined prototypes, production drawings
Outcome
Components achieved 40% weight reduction while exceeding strength requirements. Now standard in client's product line.
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