How We Work
Four phases. Ten steps. One pack your workshop can build from — first time.
Definition
Establish what needs to be built and why — before a single line is drawn.
Needs Assessment & Constraint Mapping
We start with a structured interview to establish core functional requirements, loading conditions, and physical constraints. Nothing is assumed. Every boundary condition is documented.
- Functional requirements register
- Constraint map (space, load, material)
- Project brief sign-off
Data Intake & Gap Analysis
Existing CAD data, sketches, or reference drawings are ingested and audited. We identify exactly what is missing, what is ambiguous, and what needs to be created from scratch.
- Existing data audit report
- Gap analysis matrix
- Input data register
Scope & Assumption Documentation
We formalise the project boundary and document every assumption in writing. This is the document we both sign — it protects you from scope creep and us from guessing.
- Signed scope document
- Assumption register
- Exclusion list
Design
Build the geometry right the first time — parametric, manufacturable, documented.
Parametric 3D Modelling
Robust SolidWorks models with clean, stable feature history. Designed to be modified without breaking — because requirements always change. Every mate and reference is intentional.
- SolidWorks 3D assembly model
- Part files with stable feature tree
- Model review checkpoint
Design for Manufacture Review
We evaluate every geometry against real manufacturing processes — weld access, tool clearance, bend radii, surface finish requirements. Problems caught here cost nothing. Problems caught on the shop floor cost everything.
- DFM review report
- Model revision with DFM corrections
- Material and process specification
Simulation
Validate before you fabricate — not after.
FEA Setup & Pre-Processing
Mesh generation with element quality verification. Boundary conditions applied to match real operating loads — not idealised textbook cases. Every load case is documented and justified.
- Meshed FEA model
- Load case definition document
- Boundary condition register
Virtual Stress Testing
Static structural, thermal, and dynamic analyses run to verify safety factors across all operating conditions. Results reviewed against applicable standards (AS, ISO, ASME).
- Stress distribution plots (Von Mises)
- Safety factor summary table
- Standards compliance check
Engineering Refinement
Geometry updated based on simulation findings. Stress concentrations addressed, mass optimised where possible, and the model iterated until all load cases pass. No compromises on safety factors.
- Revised 3D model
- Before/after safety factor comparison
- Final FEA validation report
Output
Documentation your workshop can actually build from — on the first attempt.
Workshop-Ready Drafting
Full 2D engineering drawing set with complete GD&T applied to ASME Y14.5. BOMs with part numbers, materials, and quantities. Flat patterns for all sheet metal. CNC-ready profiles.
- 2D drawings with full GD&T (PDF + DXF)
- Bill of materials (Excel + PDF)
- Flat patterns and cut lists
Final QA & Release
Every drawing checked against the 3D model. Dimensions verified. Title block completed. All documents compiled into a single release pack and issued with revision control. Your workshop receives one complete, unambiguous data pack.
- Checked and released drawing set
- Revision-controlled data pack (ZIP)
- Project close-out summary