Mechanical design

The mechanical design stage is a crucial phase in the industrial design process where the focus shifts from conceptualizing ideas (Conceptual Design Stage) to developing detailed and functional product blueprint. This stage involves the creation of detailed mechanical solutions and systems that will allow the product to function as intended. It bridges the gap between the conceptual design and the actual manufacturing process.

At this stage, we also turn our focus to the product's interior, particularly the correct assembly of individual elements with one another, such as the electronics and other mechanical elements. In addition, we complete the model with the necessary fixing, strengthening, and positioning elements (i.e., catches, supports, ribbing) and plan the optimal way of device assembly and taking into account service indications. We carry out all construction work using SolidWorks (engineering CAD software).

Plan of action may vary depending on type of a product to develop, but main task to do at this stage are as follow:

Initial meeting with a Client 
As communication is a crucial factor in a smooth execution of a project, this meeting allows us to develop a list of tasks, including mechanical parts, mechanisms, and details to be created, based on the most up to date vision of the product and its manufacturing that our client has. This meeting also allows to determine the number of revisions for the entire project or its elements, as well as discuss technological, mechanical, and electronic requirements. This stage allows our design team to translate functionalities into technical demands.

Estimations
After a meeting a time estimation is made. It covers the time required to create the first version of the mechanical model, it also has a list of parts or systems to design and a list of files needed at the end of this stage (3D model, flat documentation, number and purpose of prototypes etc.).
Estimation is confirmed by the client which is officially a start of a design and engineering works.

Design and Engineering
Basing on correctly designed 3D models from earlier and chosen manufacturing technology our design team gets to work on a first mechanical model.

Consultations and Research
If needed our design team consult with technologists and conduct research regarding emerging mechanical design. 

Testing and Feedback
Test of the first mechanical model takes place in order to gather feedback from users and the client. Usually it is a phase rich in prototypes.

List Of Changes
Based on feedback form tests a list of changes for version 2 of the mechanical model is made. The circle of these three actions ( tests - feedback - design changes) repeats as many times as a project needs in order to satisfy all the functional and technical requirements.

Some additional tasks at this stage maybe:

• 3D modeling under selected production technology
• Selection of mechanical and electrical components
• Selection of materials
• Selection of manufacturing technology
• Elimination of part collision 
• Assessment of product safety
• Preparing technical documentation

Next episode

Mechanical design ends with a tested by prototyping and approved 3D model ready to enter the next phase of the industrial design process which is DFM. DFM stands for “Design for Manufacturing,” and it involves fine-tuning and adjusting the final mechanical model to meet the specific demands of a chosen manufacturer. This stage requires close communication between designers and the manufacturer to ensure optimal production processes while delivering excellent aesthetics and functionality for the product.

DFM is crucial for maintaining full control over the manufacturing outcome. We offer this as a separate step to provide our clients with customized services. The DFM needs of clients with their own manufacturing facilities differ slightly from those of clients debuting in the hardware market. 

If you are not sure what stage of technological readiness your project currently is at contact us, and we will conduct an analysis and create a report showing the direction of required work