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Design Innovation can help you with mechanical design of components, subassemblies and entire products. We're ideally positioned to be an as-needed contributor to your design team. We're available when you need us.

We design for structural and performance requirements plus usability and aesthetics, with a focus on cost-effective manufacturing and assembly. Our experience covers a wide range of engineering and decorative materials, including surface finishes that are durable and attractive. Additionally, we have expertise at modifying commercially available plastic and metal enclosures for getting small to medium volume products to market at a lower cost than investing in a custom enclosure.

We're a Solidworks Manufacturing Network Partner. More about why we use Solidworks 3D CAD. We also offer writing of assembly manuals with photo and CAD illustrations, industrial photography, production documentation and consulting on product design methodology for your company.

Some examples of our design and prototyping work:

 

Image of RFID Circuitry Enclosure by Design InnovationImage of Injection Molded Shroud by Design Innovation
Ford DeWalt Tool Link RFID System - The mechanical design for this product included the injection-molded antenna shroud, several steel support brackets, a machined heatsink, two molded rubber seals, and die-cut thermal pads. We also modified an existing die-cast environmentally sealed enclosure to hold the RFID circuitry and a group of sealed connectors. All components and assemblies tested passed impact, shock/vibration and environmental tests on their first try. More about our work on Tool Link RFID, and Ford's own website about Tool Link.

Photo of Action Tracker product designed by Design InnovationImage of Action Tracker product designed by Design Innovation
ActionTracker - The mechanical and cosmetic design for this product included the injection-molded enclosure and a waterjet-cut backplate and seal assembly. We also modified an existing battery terminal to fit in an extremely small space. The ActionTracker is water and impact resistant, smaller than an iPod Nano and weighs less than 1oz.. Photo copyright 2008 by AWare Technologies Inc.

Photo of USB ReaderCAD image of USB Reader
USB RFID Reader
- For this product, an off-the-shelf enclosure was modified with holes for the pushbuttons, LEDs, USB connector and mounting hardware. A die-cut label was also created to fit in a molded recess in the enclosure top. Photo copyright 2008 by ThingMagic Inc.
Photo of Sheet Metal EMI Shields from Design InnovationImage of Sheet Metal EMI Shield from Design Innovation
Sheet Metal EMI Shields - These 2-part sheet metal EMI shields were designed for a series of embedded RFID readers. The features were extremely small and the fit of each part had to be very precise. The prototypes fit perfectly on the first try. Photo copyright 2008 by ThingMagic Inc.

Image of Lift Mechanism For A Designer Writing Desk - Up - from Design InnovationImage of Lift Mechanism For A Designer Writing Desk - Down - from Design Innovation
Lift Mechanism For A Designer Writing Desk
- This mechanism included structural parts made from stainless steel plate, plus gas springs, torsion springs, precison bushings and stainless steel and Delrin hardware. More about our work on the desk lift mechanism.

Image of Initial Concept Prorotype For The OLPC Computer Housing - News Photo - from Design InnovationImage of Initial Concept Prorotype For The OLPC Computer Housing - Motion Sequence from Design InnovationImage of Initial Concept Prorotype For The OLPC Computer Housing - Closed from Design Innovation
Initial Concept Prototype For The OLPC Computer Housing
- The mechanical and cosmetic design for this prototype included all the sheet metal and machined parts for the aluminum shell and folding mechanism, a polycarbonate display protector, sheet rubber gaskets, keyboard block, and plastic bushings and endcaps. We also sourced the sheet metal and fasteners, made all the other prototype components and assembled the prototypes. CAD simulation of the opening and closing mechanism allowed the prototypes to function perfectly from the first assembly onwards.
Laptop photo copyright 2005 USA Today.

Image of Prototype of Portable Electronic Product from Design Innovation
Prototype For A Portable Electronic Product - The design work for this product included a 4-part sheet metal enclosure, die-cut plastic and adhesive components for positioning, securing and protecting the display, and a die-cut decal for the top. Specific challenges in this project included some complex cable routing and ensuring that the design allowed adequate airflow through the unit. We built several prototypes of this device for a Boston-area R&D firm.
Image of Polycarbonate Medical Labware from Design Innovation
Polycarbonate Medical Labware - These polycarbonate containers were designed and built for a research group at Brigham and Women's Hospital in Boston and are used for holding cell culture vessels in a medical lab. The containers were designed in CAD and fabricated from polycarbonate tubes and rods with silicone rubber O-rings to provide liquid-tight seals for the cell culture vessels and adapter pieces. The adapter pieces are shown in color for visual contrast. Polycarbonate was chosen for cell culture compatibility, transparency, ability to withstand autoclaving, and ease of machining. The first units built were immediately usable after initial sterilization.
 
 
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Copyright 2002-2009 by Scott Lefton except where otherwise indicated.