Product Design
End-to-End Mechanical Design and Product Development
From concept through detailed design and verification, bringing complex mechanical systems to life under tight schedules and demanding performance requirements is challenging. Whether developing jet engine components, underwater propulsion systems, rotorcraft test equipment, or innovative firearms products, success depends on precise engineering, robust product definition, and seamless integration.
With results-driven mechanical engineers with over 30 years of experience, we provide Product Development and Design consulting that bridges innovation with practical execution. Our background includes senior roles at Pratt & Whitney, Lockheed Martin, Structural Composites, Century Arms, and EDF, Inc., where we have led the design of mission-critical systems for aerospace, undersea, and defense programs.
Why Choose Us?
- Accelerate development cycles while maintaining compliance and performance standards
- Reduce risk through expert tolerance analysis, model-based design, and design reviews
- Deliver manufacturable solutions optimized for real-world environments (deep-sea, thermal shock, high-stress, corrosive)
- Integrate innovation with disciplined engineering processes
- Benefit from hands-on leadership in both OEM and fast-paced environments
Core Product Development & Design Services
Model-Based Definition (MBD) and 3D Product Design, Develop precise 3D models and complete product definitions.
- Full 3D model-based engineering with ASME Y14.5 compliance
- Tolerance analysis, geometric studies, and stack-up evaluations
- Associative 2D drawings and seamless manufacturing integration
- Product data management in PDM systems
Complex Mechanical Systems & Component Design, Design of high-performance assemblies including:
- Jet engine components (combustors, diffusers, turbine airfoils, exhausts, nozzles)
- Underwater and sub-sea systems (towed array handling, dynamic delivery systems, oil-filled modules rated to 20,000 ft)
- Propulsion and hydraulic systems
- Mission modules and launch/recovery systems
Specialized Test Equipment & Facility Design, End-to-end development of custom test rigs and infrastructure:
- Corrosion evaluation rigs (CH-53K rotorcraft)
- Splashdown and thermal shock simulation (ORION Space Capsule)
- Propulsion test equipment and facility infrastructure
- Dynamic handling systems and sub-sea test platforms
Innovation-Driven Product Development, Act as fractional lead or advisor to accelerate R&D:
- Lightweight composites solutions for aerospace and marine logistics
- Rapid prototyping guidance and cross-functional team leadership
- Dynamic systems that deliver measurable improvements (e.g., 40% sub-sea drag reduction)
- Creative problem-solving under aggressive timelines
Independent Design Reviews & Technical Support
- Tolerance stack-up studies and manufacturability assessments
- Basis of Estimate (BoE) authoring
- CFD/power studies support
- Waterproofing and environmental test procedure development
- Representation in design reviews and stakeholder presentations
Assembly Line & Fixture Design
- Custom assembly and machining fixtures using advanced manufacturing techniques
- Value stream mapping and process optimization for efficient, traceable production
Who We Help
- Aerospace and jet engine manufacturers
- Defense contractors and naval systems integrators
- Marine and underwater vehicle companies
- Rotorcraft and propulsion programs
- Precision manufacturing and firearms developers
- Test labs and R&D organizations needing reliable equipment