3D Design, Prototyping & Simulation

CAD Design, Prototyping, and Simulation.

SolidWorks CAD design, 3D printed prototypes, tolerance and fit review, pre-production checks, and FEA simulation. As much or as little as the project requires.

Step 1 · CAD Modelling

3D CAD Design in SolidWorks

Parts and assemblies modelled with manufacturing, assembly sequence, and downstream testing considered from the start, not just geometry, but designs that can be made, measured, and tested.

Part & Assembly Modelling

New parts modelled from sketch or reference, or existing designs updated. Assembly sequences reviewed for fit and interference before anything is physically made.

Part and assembly modelling from sketch or reference file
Interference check and motion analysis
Engineering drawing and documentation package

Design for Manufacturing & Assembly

Designs reviewed for how they will be made and assembled, catching features that add cost or risk before they reach a supplier quote. Experience across injection moulding, sheet metal, machining, and extrusion.

DFM review against intended manufacturing process
Feature simplification to reduce tooling cost
Supplier-ready drawing package

Tolerances, Fits & GD&T

Tolerances specified based on manufacturing process, assembly method, and functional requirement. GD&T applied where form, fit, or function is critical, designed to be inspectable, not just drawable.

Tolerance stack-up analysis for critical interfaces
GD&T annotation on engineering drawings
Tolerances matched to supplier process capability

Step 2 · Prototyping

3D Printing & Physical Prototypes

Physical models to verify geometry, check fits, and test function before committing to production tooling. Used in patent applications, stakeholder reviews, and mechanical test programs.

FDM & 3D Printing

Functional prototypes selected for surface finish, mechanical behaviour, and intended use, with rapid iteration between design versions.

Geometry and fit verification against mating parts
Functional assembly and interface testing
Material selected to approximate production properties

Proof-of-Concept & Pre-Production Models

Physical models for stakeholder reviews, investor presentations, patent filings, and development milestone sign-offs.

Appearance and proportion models
Models suitable for mechanical test rig mounting
Documentation suitable for patent applications

Step 3 · Pre-Production Review

Design Review Before Tooling Is Ordered

Changing a drawing costs almost nothing. Changing a tool costs thousands. A structured review before production release catches the issues that are expensive to fix later.

Pre-Production Design Review

Drawing completeness, dimensions, tolerances, material callouts
Assembly interference and clearance confirmation
BOM review and revision control check
Supplier drawing package review before release

Manufacturing Readiness

Designs that work at prototype scale do not always translate cleanly to production. Draft angles, wall thickness, and supplier capability reviewed against final drawings.

Prototype-to-production design delta review
Draft, wall thickness, and gate location review for moulded parts
First-article inspection plan development

Step 4 · Simulation

FEA Simulation

Simulation used when physical testing is expensive, when a failure mode is difficult to observe directly, or when a design needs to be optimised before the next prototype. Most useful when paired with physical test data, not as a replacement for testing, but to make testing more targeted.

SolidWorks Simulation

Linear static, thermal, and fatigue analysis identifying high-stress regions and estimating service life before prototypes are built.

Static structural analysis under applied loads
Thermal analysis and fatigue life estimation
Stress concentration and design improvement

ABAQUS, Nonlinear FEA

Advanced simulation for large deformation, contact, material nonlinearity, and dynamic loading, developed through PhD-level research and industrial application.

Large deformation, contact, and dynamic simulation
Nonlinear material behaviour modelling
Custom material subroutines available, see Material Characterization

Have a design that needs to be modelled, built, or validated?

Start with what you have, a sketch, an existing file, or just a description of the problem.

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