Projects

This ongoing development project explores the mechanical design and construction of a multi-axis robotic manipulator.

The structure must provide reliable movement and mechanical strength while remaining efficient to manufacture, assemble and refine through repeated prototype cycles.

We are iterating the mechanical structure through multiple CAD and physical-prototype stages. Each version is reviewed for geometry, weight, material use, printability, assembly access and expected mechanical performance.

The project continues to progress through testing and optimisation. The objective is not only to produce a working mechanism, but a robust and manufacturable platform that can support future development.

Capabilities: robotics development, multi-part CAD assemblies, mechanical prototyping, additive manufacturing and design optimisation.

A client required durable and dimensionally precise components for a large-format 3D printer with a build volume of approximately one cubic metre.

The parts needed to support moving mechanical elements, integrate standard hardware and tolerate the loads associated with industrial equipment.

We designed reinforced components for production in glass-fibre-filled ABS. Metal bearings and threaded inserts were incorporated into the design so the printed structures could interface securely with the remaining machine assembly.

The resulting parts formed a robust, production-ready solution designed for accurate installation, mechanical loading and continued industrial use.

Capabilities: industrial CAD design, fibre-reinforced materials, bearing integration, threaded inserts and assembled printed components.

A series of custom U-profile guides was developed as an alternative to conventional aluminium extrusions.

The design needed to reduce weight and production cost while retaining sufficient structural integrity for the intended application.

We developed printable profile geometry that could be adapted quickly to different dimensions and functional requirements. The sections were refined to use material efficiently while preserving the necessary form and stiffness.

The final profiles enabled faster prototyping, lower component weight and greater freedom to customise individual guide dimensions without sourcing new aluminium sections.

Capabilities: lightweight component design, profile development, material optimisation, CAD modelling and FDM manufacturing.

A client needed a functional refrigerator shelf that could be manufactured despite limitations in available printer size.

The completed shelf was larger than the practical print area and needed to remain strong in use. Assembly also had to be straightforward and avoid permanent adhesives.

We designed a modular folding shelf divided into smaller printable sections. Interlocking features allow the parts to be assembled without glue, while the installed geometry locks the structure into a rigid final form.

The design made it possible to manufacture a large functional shelf on smaller printers while maintaining practical strength, repeatable assembly and easy handling before installation.

Capabilities: modular product design, interlocking mechanisms, design for assembly, large-part segmentation and FDM prototyping.

A client required strong and reliable replacement handles for an industrial refrigerator. The parts needed to withstand frequent daily use while fitting the existing equipment accurately.

The original mounting points had to be retained, but the replacement design needed greater strength, practical installation and a clean finished appearance.

We developed custom PETG handles with reinforced internal ribbing and a concealed fastening system. The geometry was designed around the available mounting locations and optimised for FDM production.

The completed handles provided a durable, fully functional replacement tailored to the refrigerator, with secure installation and no visible front fasteners.

Capabilities: CAD modelling, design for additive manufacturing, FDM 3D printing and functional replacement parts.

Printzilla is an in-progress large-format 3D-printer development project built around a reinforced modular aluminium structure and an approximate 1 m³ build volume.

The machine is designed to provide a substantially larger working area while retaining rigidity, serviceability and the freedom to refine individual subsystems.

The project combines mechanical-frame development, custom reinforced components, motion-system integration and repeated fit and production testing.

Printzilla remains under active construction. The motion system, print platform and remaining assemblies will continue to be tested and optimised as development progresses.

Capabilities: large-format machine development, mechanical integration, custom component manufacturing and iterative prototyping.

This project involved the assembly and practical workshop integration of a compact laser engraving system, including a custom protective enclosure and smoke extraction.

The objective was to turn a purchased component kit into a complete, practical and organised workshop system suitable for laser cutting and engraving.

The laser system was assembled and adjusted in-house. We then constructed a custom protective enclosure, installed ventilation and smoke extraction, and organised the individual components into a functional working setup.

The finished system combines the laser unit, protective enclosure and extraction system in a compact arrangement. Practical testing helped us improve the setup and prepare it for regular workshop use.

Capabilities: equipment assembly, workshop integration, custom enclosure construction, extraction-system installation and practical testing.

This project involved the development and manufacture of custom tooling for a box-forming machine. The tool supports and guides a cardboard blank while pressure is applied, helping the machine form the required box shape consistently.

The objective was to create a purpose-built tooling insert that matched the box geometry, fitted the existing machine and could withstand the forces applied during the forming process.

The geometry was refined through several printed test pieces before the full tooling body was produced. This iterative approach allowed mounting points, clearances and contact surfaces to be checked before final assembly.

The main structure was manufactured using FDM 3D printing, while steel plates were added at the contact areas to reinforce the assembly and provide more durable working surfaces.

The completed tooling was checked with the actual cardboard blank to verify its fit, alignment and contact geometry before installation on the box-forming machine.

Capabilities: custom tooling development, FDM prototyping, hybrid polymer-and-metal assemblies, fit testing and practical manufacturing support.