Engineering consulting and project delivery
Additive manufacturing consulting and engineering for complex projects
Design for additive manufacturing, prototyping, testing, compliance, programme management and manufacture from one UK engineering team, with an NDA on request. For significant projects we put together a dedicated team under a single lead, agree a detailed plan and deliver the work with you.
What an engagement covers
Services from concept design to delivery
Use one part of this or all of it. On larger programmes the disciplines run in parallel, planned together so design, testing and manufacture do not wait on each other.
Design and assembly modelling
Full 3D assembly models, interfaces, tolerances and exploded drawings for products and structures made of many parts.
Prototyping and test articles
Scale models, full-size mock-ups and representative test articles built early to answer design questions before production.
Design of testing
Test plans written from the requirement: what to measure, on which article, to what acceptance criteria, before any money is spent on the rig.
Fire and regulatory testing
We plan, specify and coordinate fire, structural and environmental testing with accredited laboratories, and manage the evidence.
Regulatory compliance
Mapping applicable regulations and standards to the design, and building the technical file an approver expects.
Programme and project management
Detailed Gantt plans, milestones, dependencies, risk and supplier coordination for complex, multi-party projects.
Manufacturing and production
Prototype to batch and series production, in additive, tooling and conventional routes, with build records.
Design for additive and tolerance
Geometry, orientation, material and GD&T chosen for what the process can hold, and reviewed before it is built.
Reverse engineering
A scan, worn part or sketch turned into a production-ready model, then improved.
Production strategy and make-or-buy
Additive against machining, moulding and tooling, with cost, lead time and risk laid out for the decision.
Example project
How a complex structure is taken from model to approval
An example use case, drawn from the way we work on large faceted structures such as our printed church dome. The drawings and plan below are illustrative of our method, not an extract from a client programme.
1. Assembly model and drawing
Every part is modelled in context, interfaces are defined and an exploded drawing with a bill of materials is issued before anything is built.
2. Programme plan
A detailed Gantt chart ties design, test, compliance and manufacture together, with decision gates where the customer, approver and team agree to proceed.
3. Test design and compliance
Testing is designed alongside the product, then run with accredited laboratories where the regulation requires it. If a test fails, the design is revised and retested without restarting the programme.
| Verification activity | What it establishes | Evidence produced |
|---|---|---|
| Structural load testing | Proof and ultimate load cases on representative articles and joints. | Load and deflection record against the design case |
| Fire reaction and surface testing | Material and assembly reaction to fire, specified to the regulation that applies. | Accredited laboratory report |
| Environmental ageing | UV, humidity and thermal cycling for parts that live outdoors. | Property retention data |
| Fit and installation trial | Full-size mock-up of the joint, interface and installation sequence. | Installation method statement |
| Dimensional verification | Measured production parts against the drawing and tolerance strategy. | Dimensional report per batch |
Fire and structural certification is carried out by accredited third parties. We design the test programme, supply and prepare the test articles, and manage the evidence for the approver.
The team
A multi-discipline team for significant projects
Design, analysis, test, manufacturing and quality engineers work under one programme lead, alongside your architects, designers, approvers and test houses.
- Design engineersCAD, assembly modelling, design for additive manufacturing and drawings.
- Analysis engineersStructural, thermal and flow studies to guide design.
- Test and complianceTest design, laboratory liaison and evidence.
- Manufacturing engineersProcess planning, tooling, production and finishing.
- QualityInspection, build records and traceability.
Also available as stand-alone consulting
| Service | You give us | You get |
|---|---|---|
| Design for additive | Your CAD model and its function | Geometry, orientation and support strategy chosen to cut cost and lead time |
| Reverse engineering | A scan, a worn part or a sketch | A production-ready CAD model |
| Tolerance and GD&T | The drawing and the fit it has to make | A dimensional strategy that matches what the process can hold |
| Production strategy | Volumes, requirements and a target cost | A comparison of additive against machining and tooling |
Sectors we advise
- AerospaceWeight and traceability requirements.
- DefenceConfidential programmes. NDA on request.
- AutomotivePrototype to production planning.
- Robotics and automationMechanism and assembly design.
- Medical and healthcareControlled, traceable components.
- Energy and nuclearTooling and replacement parts.
Frequently asked questions
Can you run a whole project, not just advise?
Yes. For significant projects we provide a programme lead and design, analysis, test and manufacturing engineers as one team, with a detailed plan, milestones and risk register. You can also take just the part you need.
Do you carry out fire and regulatory testing?
Certification testing is carried out by accredited laboratories. We design the test programme, build and prepare the test articles, coordinate the laboratory and manage the evidence for approval.
Do I have to manufacture with you?
No. Our advice applies whether the part is made by us, in-house or by another supplier.
Can you work under NDA?
Yes, NDAs are available on request.
Can you challenge a design that already exists?
Yes. Reviewing an existing drawing for manufacturability, tolerance and cost is one of the most common requests.
Related guides
Send a difficult part for review
Send a CAD file, a scan or a worn part. An engineer replies with what needs to change.