Mechanical Engineering

Design, Analysis, and Manufacturability are three inseparable components of our mechanical engineering.

Part & Product Design

Electronics, medical, and consumer products are the industries that we focus on the most. Pro/Engineer and SolidWorks are used as our CAD (Computer Aided Design) software.

Our design engineers are highly skilled in modeling all kinds of forms, from organic shapes to advanced mathematical configurations. An example of a more complex form designed by D4E using Pro Engineer is the vane impeller with an involute shape. These were modeled using formulas combined with coding in Pro Engineer to achieve fluid dynamic characteristics.

Impeller modelled using formulas and Pro/E coding

We work closely with industrial designers and acoustic engineers to achieve high-quality acoustic consumer electronics. The following high-end headset designed for FIFA referees is an excellent example. It needs to fit very snugly and comfortably while conducting loud and clear sound into the inner ear. It clings to the ear at three locations: two at the concha and one at the ear canal, allowing a wide range of adjustment for user preference.

Boom MIC headset, for Nautic Devices

S-911 Enforcer for Laipac

In mechanical design for electronics, we have an abundance of experience in meeting stringent product requirements such as IP ratings as well as shock and vibrations. During design process, we pay special attention to the human factors involved as well as the security features as shown in the following GPS tracker for paroling.

Structural Analysis

At D4E, we are proficient at structural analysis by using simulation, an important step in design of parts that undergo extreme load or temperature conditions. FEA (Finite Element Analysis) software is used for this purpose. The following figure shows internal behavior under stress of the in-ground parking monitor.

FEA result on the housing of the parking monitor, for Park Assist Ltd

After simulation, we will make physical parts using prototype tooling if 100% accuracy is required. For instance, various materials were tested using for the following parking monitor, including glass-filled nylon and poly-carbonate. The stringent requirements were finally met by using a Xenoy resin.

Various materials were tested for the parking monitor, for Park Assist Ltd

Design for Manufacturability (DFM)

Our team combines creativity with problem solving and engineering skills to meet complex tooling and design challenges. At D4E, we model rough molds in 3D quickly. They are used in studying feasibility and structural soundness. We analyze manufacturability, determine cost as it relates to quantity, and compare alternative manufacturing processes.

Rough tooling 3D model and a prototype tooling part for chipping protector for Honda R&D Americas

Mold-flow analysis is conducted by our experienced tooling engineers. For example, the mold-flow analysis of the Sprng earbud was used for design and manufacturing this 2-shot part consisting of a rubber over-molding with a polypropylene substrate. The challenges are combination several factors: the complexity of the 2-shot, the unique organic shape, and some very thin areas that cannot be gated due to the contact of human skin.

Left: Mold-flow analysis for Sprng Earbud Clip. Right: Sprng Earbud Clip, for OHM Industrial Designers

OHM Industrial Designer created the industrial design and mechanical design for this rugged radio set: IP 67 and shock & vibration. To meet more challenges specific to this device, it uses no screws for the shell and the water-tight seal is done by 2-shot. We successfully delivered the DFM and the product is in steady production.

Yapalong5000 radio, for Nautic Devices