Mechanical Design and Automation

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ABOUT US

WHO WE ARE

We are a skilled engineering team with decades of experience spanning industries such as aerospace, medical devices, consumer products, and agriculture. Our diverse background enables us to craft highly customized solutions that meet the unique needs of each client.

Our Expertise

With expertise in machine design, control systems, manufacturing engineering, LEAN manufacturing principles, and supply chain management, our team is equipped to handle every stage of the project lifecycle. From initial quoting and design to vendor selection, fabrication, installation, and final commissioning, we ensure that every step is executed with precision and attention to detail. Our extensive experience in sourcing and budget management also allows us to navigate complex challenges and deliver solutions that are both cost-effective and high performing.

Our Approach

At the core of our process is a deep commitment to understanding the specific needs of our clients. We work closely with each customer to assess their requirements, ensuring that the solutions we design are not only technically sound but also aligned with their budget, timeline, and quality goals. Whether it's optimizing production efficiency, meeting strict regulatory standards, or building systems that scale with growth, we focus on delivering a solution that works for the customer—tailored to their unique challenges.

OUR TECHNICAL EXPERTISE

Our team draws on a wide range of tools and processes that enable us to deliver effective, customized solutions for every project. We're committed to staying at the forefront of technological advancements and continually expanding our skill set. Some of the key tools and capabilities we bring to every project include:

SolidWorks CAD Design and Simulation: Using advanced SolidWorks tools for precise design, 3D modeling, and simulation to ensure that every custom solution meets the required specifications before fabrication begins.
Electrical Design and Implementation: Expertise in designing and implementing electrical systems, ensuring seamless integration with mechanical components and reliable system performance.
Assembly and Tuning of Machines: Hands-on experience in the assembly and fine-tuning of custom machines, ensuring they perform optimally and meet client requirements.
Fabrication, Welding, and Machining: Real-world experience with fabrication processes, welding techniques, and machining, allowing us to create robust, high-quality components.
Collaborative Robot Integration: Proficiency in integrating collaborative robots (cobots) to automate processes, increase productivity, and improve safety in the workplace.
PLC Programming: Expertise in PLC programming (Allen Bradley, IDEC, and other platforms), allowing us to create reliable and flexible control systems that automate operations and improve process efficiency.
GD&T and Metrology Techniques: Skilled in Geometric Dimensioning and Tolerancing (GD&T) and metrology techniques to ensure precision and high-quality standards in every project.

These capabilities allow us to design and build machines that meet the specific needs of our clients, whether it’s automating an assembly line, improving manufacturing processes, or integrating new technologies. We’re always looking for ways to expand our skills and improve the solutions we provide.

PROJECT CASE STUDIES

Wire Mesh Forming Machine

Client: Agricultural Equipment Manufacturer

Project Overview:
Our client, an agricultural equipment manufacturer, had a complex wireform design that needed to be manufactured in large volumes. Although the design had been perfected over time to meet their specific needs, the client’s existing manufacturing method was outdated and causing significant operational inefficiencies.

Challenge:
The client’s existing machine was constantly breaking down, leading to frequent unplanned downtime and costly maintenance. Additionally, the machine was difficult to adjust and required extensive troubleshooting whenever raw material varied, further impacting production. With these ongoing reliability and usability problems, the client needed a solution that could deliver consistent, high-volume production without compromising on quality or efficiency.

Solution:
We developed a custom machine that addressed both the design complexity and the reliability issues of the previous system. Key improvements include:

Modern PLC Controls: Replacing outdated controls with advanced PLC systems, providing more precise and adjustable control over the forming process.
Servo Positioning and Pneumatic Actuators: These components ensure accurate, repeatable part formation and reduce mechanical strain, improving both performance and longevity of the machine.
Sensors with Predictive Maintenance Tracking: Sensors were integrated to monitor machine health in real-time. These sensors track key components and operational metrics, alerting operators when maintenance is required, before issues lead to breakdowns. This proactive approach to maintenance reduces costly downtime and ensures the machine runs at optimal efficiency.
Ease of Maintenance: The new design incorporates user-friendly components, modular parts, and clear maintenance protocols, simplifying upkeep and reducing the frequency of unscheduled repairs.
ISO Safety Standards: The new machine meets all ISO safety standards, ensuring the well-being of operators with integrated safety controls and guarding.
Automatic Stacking System: A major innovation was the addition of an automatic stacking system that enables the machine to operate unattended, allowing for higher throughput and reduced reliance on labor.

Outcome:
The new wire mesh forming machine eliminated the frequent breakdowns and maintenance headaches that plagued the previous system. With improved reliability and predictive maintenance alerts, the client now enjoys higher productivity, reduced downtime, and lower maintenance costs. The automatic stacking system further enhanced efficiency by enabling autonomous production, freeing up labor resources.

Catheter Assembly AiD

Client: Medical Device Company

Project Overview:
Our client, a medical device company, developed a new catheter design that needed to be assembled at production scale. The innovative design involved several very small parts, and the assembly process required significant manual labor.

Challenge:
The catheter design required two extremely small but long, rectangular wires to be inserted into corresponding guide tubes on the device. Given the size and precision required, these wires could not be oriented incorrectly, twisted, or kinked. Handling such small components posed a significant challenge for operators, making it difficult to manually insert the wires with consistency.

Solution:
We engineered a custom machine that addressed these unique challenges while improving both efficiency and quality. Key features of the machine include:

Medical-Grade Materials: All components of the machine are made from medical-grade materials, ensuring that the assembly process meets the stringent cleanliness standards required in the medical device industry.
User-Friendly Fixturing System: The fixturing system was designed to be easy to load and operate, ensuring quick setup and minimal downtime for operators.
Orientation and Alignment Control: The machine design incorporates mechanisms to prevent wire misorientation, twisting, or kinking during the insertion process, ensuring precise assembly every time.
Gentle, Effective Drive System: The drive system is specifically engineered to push the wires into the assembly tubes without damaging them, preventing kinks or stress on the wires during insertion.
ISO-Compliant Controls and Safety: The system is equipped with ISO-grade controls and safety equipment to ensure that the machine operates safely and reliably.

Outcome:
The new catheter assembly machine significantly reduces the difficult and repetitive manual work for operators, while improving the consistency and accuracy of the assembly process. By integrating machine-assisted assembly with operator involvement, the process achieves a large reduction in labor costs, all without requiring excessive capital investment in fully automated systems. The result is a more efficient, cost-effective production process that maintains high-quality standards for the medical device assembly.

Hops Picking Machine - Design & Iterative Improvements

Client: Dauenhauer Manufacturing

Project Overview:
Since 2018, we’ve partnered with DMFG, a company that produces large, complex harvesting machines. They typically build one or two of these systems per year, each designed to meet unique customer requirements. Over this long-term collaboration, we have been involved in the continuous improvement and iteration of each of the machine’s subsystems to optimize performance, reduce assembly time, and address long-term reliability issues.

Challenge:
One of the major challenges was the lack of engineering data for the existing machine. The existing design relied on old paper drawings and inadequate or incomplete CAD models, which made it difficult to get accurate measurements and understand the full scope of the system. With over 30,000 parts in the machine, reverse engineering many components was necessary. We spent significant time measuring existing parts, updating outdated CAD models, and interpreting the original drawings to gather the required data for the redesign.

In addition to the data challenges, the machine had numerous moving parts, complex drive systems, and exposed mechanisms that made it difficult to assemble, maintain, and scale. The original assembly process took around six months to complete, incurring significant labor costs. The outdated drive systems and complex structural design also posed maintenance challenges, causing excessive downtime and making the machine difficult to service.

Solution:
Since 2018, we have worked together to make continuous improvements in both the design and the manufacturing process. Some of the key enhancements include:

Assembly Time Reduction: One of the most significant improvements was in assembly time. Through design updates and a streamlined assembly process, we reduced the build time from six months down to just two months. This was achieved by simplifying the structure, improving subassembly processes, and standardizing key components.
Modernized Design & Materials: The design was modernized to take advantage of current manufacturing techniques and materials, making the system more durable and higher quality. Finite Element Analysis (FEA) was used to optimize the structural design and ensure that the machine would remain robust while also being easier to build.
Improved Drive Systems: Previously, the machine used complex chain and belt drives to run multiple components. We replaced these with individual gearboxes for each drive, which made the system more reliable, easier to maintain, and significantly reduced maintenance costs. This also contributed to a safer machine, as fewer exposed moving parts were present.
Supplier Development: Due to the scale and complexity of the machine, it wasn’t feasible to design and build every part in-house. We worked closely with the client to identify and develop relationships with new suppliers who could provide specialized components. This included finding vendors with advanced technologies and new materials that allowed us to improve problematic areas of the machine.
Job Site Support: Given the machine’s size and complexity, we spent extensive time on the job site with the client’s assembly team, helping to assemble the machine and solve problems as they arose. This hands-on involvement allowed us to see the issues firsthand, learn from the challenges, and implement solutions for future iterations. This collaboration was highly valued by the client’s technicians, as it helped streamline assembly and troubleshooting for subsequent systems.

Outcome:
As a result of the ongoing improvements and close collaboration, the machine has become more efficient, reliable, and cost-effective in the long term. While the overall cost of the machine has increased due to the design upgrades and use of modern materials, the changes significantly reduce long-term maintenance costs and improve reliability. The assembly time has been cut by more than half, leading to faster turnaround times for the client. The new drive system is easier to maintain, more durable, and has substantially reduced downtime. Additionally, the overall safety of the system has improved with fewer exposed moving parts. The partnership with new suppliers has allowed for better quality components, which, despite the higher initial cost, results in a more cost-effective solution over the machine's lifetime due to reduced maintenance and operational expenses.