Core Mechanical Design

Menu
Free project consultation

Frolick baby teether

// Frolick baby teether

Give them something to drooool over.

We developed a prototype concept into a fully certified, volume-production consumer product. The core challenge was engineering a complex dual-material overmoulded design that needed to be structurally rigid in some areas whilst remaining soft and safe for chewing in others – all while meeting stringent FDA material approvals and passing rigorous choke hazard testing.

The product is now in full volume production and sold worldwide.

Start a Project now
img
Extra_Toothi_Dusty_Rose_1
11
8_2
2._Toothi_Denim_Blue

// The problem & the solution

The Core Challenge & Solution

The Problem

Bringing a Safety-Critical Baby Product to Market

img

Dual-Material Design: The product needed to combine a rigid structural core with soft chewable zones - requiring an overmoulding process that had to work consistently in volume production.

img

Manufacturing Complexity: Achieving reliable bonding between two dissimilar materials in an overmoulding process at scale, without defects or delamination.

img

Regulatory Compliance: All materials had to be FDA approved and free from harmful substances, with full documentation for market access.

img

Safety Testing: The geometry had to be engineered to pass rigorous choke hazard standards, requiring careful optimisation of dimensions and form.

The Solution

Precision Overmoulding, Certified for Production

img

Engineered an innovative overmoulding approach that achieved reliable dual-material construction at volume, with rigid core and soft chewable zones performing exactly as required.

img

Selected FDA-approved material combinations that met all regulatory requirements whilst delivering the tactile and durability properties needed for a baby product.

img

Optimised the geometry through iterative design to pass choke hazard and safety testing, giving the client a clear route to market.

img

Supported the full transition from prototype to volume production. The product is now sold globally by Frolik+Co (frolikandco.com).

// Technical Highlights

Precision Engineering

Focus Engineering Action Result
Dual-Material Construction
Engineered overmoulding process for rigid/soft zones
Consistent, defect-free production parts
FDA Compliance
Specified approved material grades
Full regulatory clearance for baby product market
Choke Hazard Testing
Geometry optimised through iterative design
Passed all required safety standards
Production Transition
DFM-led design and supplier coordination
Full volume production, sold globally

// Value Delivered & Results

From Concept to Reliable Tool

For the Client

  • Delivered a certified, production-ready product that passed all safety and regulatory requirements, and successfully launched into the consumer market.

For the End User

  • A safe, FDA-compliant teether with a dual-material design that provides the right stiffness and softness exactly where a baby needs it.

Key Outcome

  • The product is now sold in volume worldwide by Frolik+Co.
free product strategy call
img

Swivel GoPro Mount

// Swivel GoPro Mount

A Swivel Mount for Demanding Shots

Designed and engineered a compact, professional-grade swivel mount that provides smooth, secure camera positioning for dynamic filming, from a simple consumer accessory to a reliable tool.
Start a Project now
img
img
  • Motion Range Full 360° swivel
  • Locking Mechanism Tool-free, positive lock
  • Mount Standard Universal GoPro-compatible
  • Design Focus CNC-machined durability

// The problem & the solution

The Core Challenge & Solution

The Problem

Stability Meets Adjustability

img

Wobble & Play: Cheap mounts often have loose joints that cause shaky, unstable footage.

img

Limited Positions: Fixed angles restrict creative camera placement.

img

Bulkiness: Many sturdy mounts are too large and heavy for streamlined setups.

img

Durability: Components must withstand vibration, impacts, and outdoor elements.

The Solution

A Single Chassis, Endless Adjustment

img

Precision Bearing Surface: Designed a smooth, low-friction swivel joint for easy one-handed adjustment.

img

Positive locking: Added a secure, tool-free cam/knob lock to hold angles firmly without slipping.

img

Optimized Footprint: Kept the design compact and lightweight without sacrificing strength.

img

Robust Interface: Used GoPro-style mounting fingers for universal compatibility and a rock-solid fit.

case-1-gal-img-1
case-1-gal-img-2
case-1-gal-img-3
case-1-gal-img-2
case-1-gal-img-3
case1-img-2

// Technical Highlights

Precision Engineering

Focus Engineering Action Result
Smooth Motion
Precision-machined bearing surfaces
Easy, single-handed swivel
Universal Fit
Over-center cam / friction-lock mechanism
Vibration-proof angle hold
Compact Strength
FEA-optimized geometry
Strong, lightweight structure
Production Ready
CNC + injection-molding-friendly design
Scalable, cost-efficient manufacturing

// Value Delivered & Results

From Concept to Reliable Tool

For the Filmmaker

  • Provides studio-smooth adjustment and rock-solid stability for professional-quality footage in any environment.

For the Client

  • Delivered a production-ready design that was optimized for cost, quality, and scalability from day one.

Key Features Validated

  • The final prototype achieved seamless 360° rotation, a secure lock under load, and passed standard durability testing.
free product strategy call
img

Electrical Switchgear

// Electrical Switchgear

Bringing Remote Control to Legacy Grid Switchgear

Partnered with a client to modernize the UK’s aging electrical infrastructure by designing the mechanical systems that enable their remote actuators to be retrofitted onto 1960s-era switchgear, drastically reducing outage times.
Start a Project now
img
img
  • Infrastructure Era Original Design (1960s): Predates CAD, remote operation, and digital records.
  • On-Site Process Reverse-engineered from scratch
  • Core Fix Epicyclic gearbox redesigned
  • Deployment Adaptable to multiple units

// The problem & the solution

The Core Challenge & Solution

The Problem

Aging Infrastructure and Manual Mayhem

img

Antiquated Operation: Maintenance needed on-site technicians and manual tools, causing long outages.

img

No Digital Records: Original technical drawings were missing.

img

Durability Issues: New actuator’s epicyclic gearbox faced design and manufacturing failures.

img

Physical Complexity: Had to create universal mounts for diverse switchgear models nationwide.

The Solution

Reverse-Engineering and Robust Redesign

img

Reverse Engineering: Measured switchgear to create 3D CAD models.

img

Universal Mounts: Designed brackets for one actuator across multiple units.

img

Gearbox Fix: Redesigned and 3D-printed prototypes for validation.

img

Prototyping to Production: Managed low-volume runs.

case2-gal-4
case2-gal-3
case2-gal-2
img

// Technical Highlights

From Field Measurement to Finished Part

Focus Engineering Action Result
Legacy Integration
Reverse-engineered 1960s switchgear on-site
Created a digital foundation for retrofit
Universal Mounting
Designed adaptable brackets & tooling
One actuator fits nationwide
Core Mechanism Fix
Redesigned gearbox and validated with 3D prints.
Resolved key durability issues
Low-Volume Production
Managed prototype to fabricated parts
Delivered functional, installable hardware

// Value Delivered & Results

Reliable Remote Control for a Critical Grid

For the Grid & Public

  • Enabled the remote monitoring and control of old switchgear, slashing outage times from hours to potentially minutes.

For the Client

  • Fixed gearbox, added universal brackets, delivered production-ready system.

Engineering Achievement

  • Bridged a 70-year technology gap with practical mechanical design.
free product strategy call
img

Go-Kart Simulator Design

// Go-Kart Simulator Design

Turned a basic rig into an immersive go-kart simulator.

Update a basic aluminum frame to look and feel like a real kart, while making it fully adjustable for all users.
Start a Project now
img
img
  • Real Kart Chassis Created an instantly authentic & immersive experience.
  • One Adjustable Design Cut client costs by replacing multiple product versions.
  • True Kart Pedal Feel Gave users realistic ergonomics and control feedback.
  • Production-Optimized Ensured reliable, cost-effective manufacturing.

// The problem & the solution

The Core Challenge & Solution

The Problem

From Functional Frame to Immersive Experience

img

Not Immersive: Looked industrial, not like a real go-kart.

img

Inflexible: Required multiple versions for different user sizes.

img

Complex to Sell & Stock: Managing different products for kids and adults.

The Solution

A Single Chassis, Endless Adjustment

img

1. Real Kart Chassis Integration

  • Used a standard go-kart frame as the core for authentic looks and feel.
  • Result: An instantly immersive racing experience.

    • img

    2. Universal Adjustability

  • Designed custom brackets to fit all existing hardware onto one chassis.
  • Result: One product fits users from small children to large adults.

    • img

    3. Realistic Pedal Design

  • Engineered a fully adjustable pedal box that replicates real kart ergonomics and pedal feel.
  • Result: Fine-tuned control and authentic feedback for the driver.

    • port-2-gal-2
    port-2-gal-3
    port-2-gal-1
    port-2-gal-3

    // Technical Highlights

    Precision Engineering

    Focus Engineering Action Result
    Authentic Core
    Built on a real go-kart chassis.
    Instant immersion.
    Universal Fit
    Created adjustable mounting brackets.
    One product fits all, cutting costs.
    True Driver Feel
    Engineered a tunable kart-style pedal box.
    Realistic ergonomics and feedback.
    Smart Production
    Designed for CNC machining & easy assembly.
    Reliable, cost-effective manufacturing.

    // Results & Impact

    Smart Design,
    Tangible Benefits

    For the Client

    • Replaced multiple product SKUs with a single adjustable design, reducing stock complexity and manufacturing cost.

    For the User

    • One chassis now fits children through to large adults, delivering an authentic kart feel for every driver.

    Production Ready

    • The design was fully optimised for CNC machining and straightforward assembly from day one.
    free product strategy call

    ELÄA

    // ELÄA Luxury Pen

    The Mechanics of a Luxury Pen

    We partnered with ELÄA to reimagine a traditional Middle Eastern stylus, engineering all internal mechanics, the user interface, and an ingenious ‘floating’ display base for a serialised, high-value collectible pen.

    Start a Project now
    img
    img
    • Production Run 71 uniquely serialized pens
    • User Experience Fine-pitch threads for smooth operation
    • Display Ingenuity "Floating" base design
    • Proven Prestige Featured at 2022 Dubai Expo VIP

    // The problem & the solution

    The Core Challenge & Solution

    The Problem

    Engineering Luxury at Micro Scale

    img

    Concealing the Mechanics: The internal workings needed to be completely hidden to preserve the traditional palm-frond-inspired aesthetic.

    img

    Achieving Premium Feel: The lid rotation, torque, and engagement needed to feel genuinely luxurious, not like an ordinary pen.

    img

    Micro-Scale Precision: Fine threads and internal fits had to work consistently at small scale, with no rattle or slop in cartridge replacement.

    img

    The Floating Illusion: The display base needed to make the pen appear to hover, requiring exact machining tolerances to achieve the effect reliably.

    The Solution

    Invisible Engineering for a Tangible Experience

    img

    Collaborative Concepting: Partnered with the client to define key design elements for brand and user experience.

    img

    Micro-Mechanical Design: Engineered fine-pitch threads and internal mechanisms for smooth, precise operation.

    img

    Floating Base: Machined components to make the pen appear to hover through exact alignment.

    img

    Finish & Coating: Selected barrel finishes combining traditional aesthetics with modern durability.

    case-5-gal-1
    case-5-gal-3
    case-5-gal-4
    case-5-gal-5
    case-5-gal-6
    case-5-gal-7
    img

    // Technical Highlights

    The Details Behind the Luxury

    Focus Engineering Action Result
    User Interface
    Engineered lid engagement (turns, torque, feel)
    Smooth, satisfying user experience
    Internal Architecture
    Designed fine threads and cartridge system
    Easy cartridge replacement, solid ergonomic feel
    Visual Illusion
    Precision-machined floating base
    Captivating, eye-catching display
    Aesthetic Durability
    Applied traditional-style durable coatings
    Timeless look that withstands handling

    // Value Delivered & Results

    A Collectible Defined by Its Engineering

    For ELÄA:

    • Delivered a production-ready mechanical system blending luxury and functionality.

    For the End User

    • Crafted a premium tactile experience, from weight to lid rotation, enhancing its collectible value.

    Proof of Prestige

    • Pen featured on the VIP sign-in book at Expo 2022 Dubai, used by high-profile guests.
    free product strategy call
    img

    McLaren Artura DCT

    // Dual Clutch Transmission Design

    Precision Housings for an 8-Speed Supercar DCT

    Joined a major automotive program to transform basic prototype housings into highly complex, production-optimized castings that reliably contain the extreme forces of a high-performance dual-clutch transmission.
    Start a Project now
    img
    img
    • Project Duration Multi-year program
    • Gearbox Speeds 8-Speed DCT
    • System Leadership Authored full gearbox PDS
    • Core Components Complex stressed castings

    // The problem & the solution

    The Core Challenge & Solution

    The Problem

    From Prototype Block to Precision Core

    img

    Basic Architecture: Early housings were blocky and not yet optimized.

    img

    Extreme Loads: Had to endure high shifting forces and engine torque.

    img

    System Complexity: Needed to hold many parts with tight tolerances.

    img

    Production Gateway: Designed for scalable casting and CNC machining.

    The Solution

    A Holistic Design, Analysis, and Production Partnership

    img

    System Leadership: Created the master PDS to align the entire gearbox design.

    img

    Integrated Design: Collaborated with all system owners to refine housings and resolve space conflicts.

    img

    Analysis-Driven: Used FEA throughout to balance strength and weight.

    img

    Production Partnership: Applied DFM in close collaboration with casting suppliers and machinists.

    img
    img
    img

    // Technical Highlights

    From Specification to Signed-Off Part

    Focus Engineering Action Result
    System Integration
    Created gearbox PDS and aligned housings
    Cohesive core for hundreds of parts
    Strength & Weight
    Applied FEA in design
    Strong, lightweight castings
    Production Viability
    DFM with suppliers
    Ready for volume manufacturing
    Quality Assurance
    Inspected prototypes
    Parts met design and tolerance requirements

    // Value Delivered & Results

    A Production-Ready Transmission Core

    For the Program

    • Led gearbox engineering, owning the core structure from spec to production sign-off.

    For Performance

    • Delivered lightweight, strong housings built to handle supercar-level loads.

    For Manufacturing

    • Bridged prototype to production, optimizing the design for casting and machining.
    free product strategy call

    Crux Wheels

    // 3-piece-wheels

    Engineering a Modular 3-Piece Performance Wheel System

    A high-performance automotive client needed a modular 3-piece wheel system that balanced weight reduction with structural integrity and simplified assembly for custom fitment applications. This case study details how we engineered a solution from initial concept to production-ready design.
    Start a Project now
    img
    • Weight Reduction 18% vs. reference design
    • Part Count Optimized assembly
    • Customization Multiple barrel/center combinations
    • Industry High-Performance Automotive

    // The problem & the solution

    The Core Challenge & Solution

    The Problem

    Why Existing Wheels Fell Short

    img

    Too Heavy: Hurt vehicle performance and efficiency

    img

    Complex to Assemble: Many small parts increased cost and time

    img

    Hard to Customize: Limited options for different vehicle fitments

    The Solution

    Smart Engineering, Simple Assembly

    img

    1. Weight-Optimized Design

  • Used FEA analysis to strategically remove material
  • Result: 18% weight reduction while maintaining strength

    • img

    2. Simplified Assembly

  • Replaced 24+ small fasteners with one locking ring
  • Result: 30% faster assembly time

    • img

    3. Modular System

  • Standardized interface allows endless barrel/center combinations
  • Result: Custom fitments from simple components

    • img
    3pie-gal-2
    3pie-gal-3
    3pie-gal-4
    port-gl-last
    img
    3pie-gal-2
    3pie-gal-3
    3pie-gal-4
    port-gl-last

    // Technical Highlights

    Precision Engineering

    Aspect Solution Benefit
    Weight
    FEA-optimized spokes
    18% lighter
    Assembly
    Single locking ring
    30% faster build
    Materials
    Forged aluminum alloys
    Strength + lightness
    Customization
    Modular interface
    Parts met design and tolerance requirements

    // Results & Impact

    Performance Delivered

    For the Driver:

    • Better handling from reduced unsprung weight
    • More customization options

    For the Manufacturer:

    • Faster, simpler production
    • Lower inventory costs
    • Stronger, safer product
    free product strategy call

    Start Your Mechanical
    Design Project

    Start your Project now
    Download Our Service Overview PDF

    Trusted by Leading Brands

    brand-logo-1
    brand-logo-2
    brand-logo-2
    img