How We Do It

A practical process for turning ideas into working designs

Every project is different, but the basic approach is the same.

We start by understanding what you’re trying to achieve, work through the mechanical problems, develop and test the design, then take it as far towards manufacture as the project requires.

You don’t need to arrive with a complete specification. Often, working out exactly what needs to be designed is part of the job.

1. Understand the problem

Get clear on what the product actually needs to do

Before jumping into CAD, I want to understand the product, the user, the constraints and what success looks like.

That might involve:

• Reviewing an existing concept or design

• Discussing how the product needs to function

• Identifying technical constraints

• Understanding size, weight, cost or manufacturing requirements

• Looking at existing products or mechanisms

• Identifying the biggest technical risks

The aim is to solve the right problem before spending time developing the wrong solution.

2. Develop the concept

Work out the simplest practical way to make it work

Once the problem is understood, I develop and evaluate possible mechanical solutions.

Depending on the project, that can involve sketches, layouts, mechanisms, 3D CAD models and early engineering calculations.

The focus is on finding a solution that is practical rather than unnecessarily complicated.

At this stage we’re asking:

Can it work?

Can it fit?

Can it be made?

And is there a better way to do it?

3. Engineer the design

Turn the concept into a detailed mechanical design

Once we have a direction worth pursuing, the design can be developed in more detail.

That may include:

• 3D CAD modelling

• Component and assembly design

• Material selection

• Mechanism development

• Engineering calculations

• FEA or motion analysis where useful

• Fasteners and purchased components

• Design for manufacture and assembly

• Detailed engineering drawings

The level of detail depends on what the project actually needs.

4. Prototype and test

Find the problems while they’re still cheap to fix

For many products, the next step is to build and test something physical.

A prototype doesn’t always need to look finished. Its job is to answer questions.

Does the mechanism work?

Does everything fit?

Is it comfortable to use?

Is it strong enough?

Can it be assembled?

What needs changing?

Testing gives us real information to improve the next version of the design.

5. Refine and prepare for manufacture

Turn what we’ve learned into a better product

Once the design has been tested, I can refine it around the manufacturing process, materials, assembly and real-world use.

Depending on the project, this may include:

• Design changes following testing

• Simplifying components

• Reducing part count

• Improving manufacturability

• Preparing production drawings

• Working with manufacturers or suppliers

• Reviewing first-off or production parts

Some clients need support all the way through this stage.

Others only need me for one part of the journey.

Both are fine.

You don’t have to start at Step 1

Already part-way through the project?

Not every client arrives with an idea on a blank piece of paper.

You may already have CAD, a prototype or an existing product that isn’t working as well as it should.

Or your internal engineering team may simply need another experienced pair of hands.

I can step into the project where you need me, solve the problem and work alongside your existing team.

Direct communication throughout

You work with the person doing the engineering

I handle the design work myself, so you’re not explaining the project to one person and having someone else interpret it later.

We can discuss problems directly, make decisions quickly and keep the engineering moving.

That’s particularly useful during development, where the answer often changes as new information becomes available.

Not sure what the next step should be?

Send me what you’ve got.

It could be a sketch, CAD model, prototype, existing product or simply an idea you’re trying to work through.

I can help you work out what needs to happen next.

Email: contact@3dmdesign.co.nz
Phone: +64 4 2376 591