Our Mechanical Engineering Experts
We are specialists at finding reliable solutions to even the most challenging structures, materials and environments of use. Our talented engineering team combines technical expertise with creative problem-solving to deliver products that perform predictably with precision, meet regulatory requirements and manufacturing tolerances – making the impossible possible.
Trusted to develop manufacture-ready connected products for Companies, Start-Ups, and Entrepreneurs
Deep Mechanical Know how is at the Center of Physical Product Design
Our mechanical experts work closely with our electronics and software teams to innovate and solve complex technical challenges to reduce product development time and minimize budget changes.
Our Creative Physical Design Team Finds Solutions for Challenging Opportunities
Our process and integrated team find good solutions that avoid costly delays and manufacturing issues:
- 3D modeling and FEA/CFD simulations predict performance before prototyping
- We do custom robotic mechanisms, confined spaces, demanding environments
- Materials selection for manufacturing process, durability, weight, performance…
- Sensor design-integration, even in harsh environments requiring IP67+ protection
- Testing to protocols for drop, shock, thermal, transport, ingress protection..
Mechanical Design Services and Specializations
Delivering precision mechanical design expertise to solve your most challenging technical requirements.
Advanced Simulation and Analysis
Validating designs through virtual testing before physical prototyping:
- Finite Element Analysis (FEA) for structural integrity
- Optimize fluid flow –air/water… using CFD tool
- Multi-body dynamics simulation
- Virtual drop and impact testing
- Thermal imaging analysis
- Digital twin simulation
- Pressure vessel and hydraulic system simulation
- Vibration analysis and modal frequency testing
Robotics and Automation Systems
Engineering precise mechanical systems for controlled movement:
- Collaborative robot (cobot) design
- Custom gantry systems with multi-axis control
- Articulated arm mechanisms
- End-effector and tooling design
- Actuator selection and integration
- Sealed rotary joint systems
- Industrial automation systems
- Rugged mobile platforms
Mechanism Design and Complex Systems
Solving precise motion challenges with innovative mechanical solutions:
- Custom gearbox and power transmission design
- Miniaturized mechanisms when space-constrained
- Ruggedized enclosures with IP-rated protection
- Kinematic linkage systems
- Custom latching and quick-release mechanisms
- Hermetically sealed systems
- Spring and elastomer design
- Energy-efficient mechanical systems
Design for Manufacturing (DFM)
Optimizing designs for efficient production and assembly:
- Material selection for best fit situation requirements
- Injection molding optimization
- Sheet metal design
- CNC machining specifications
- Manufacturing feasibility assessments
- GD&T implementation
- Design for assembly (DFA)
- Tooling and fixture design
What Clients Say About Working With Design 1st
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Richard Mineo CEO, Swabbot Solutions LLC 
Design 1st Exceeds Expectations in Responsiveness
Read Case StudyDesign 1st took our Cobot from initial concept through final product testing, handling electrical, mechanical, software, and manufacturing needs all in one team. They efficiently developed our tank access system, finalized our swabbing robot, and created a benchtop version, keeping us updated and responding quickly to every change request.
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George Tsintzouras Director of Product, Christie Digital 
Immediately understood what was needed
Read Case StudyWhen we wanted to transition our older generation projector models to a more modern look and feel, Design 1st was a valuable asset. Given the depth of their design and engineering experience, Design 1st immediately understood what was needed. They worked with our internal engineering team through the process to provide us with compatible solutions to meet our needs.
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Stephen Rayment VP Engineering, Ericsson 
Our trusted engineering partner for six years
Read Case StudyDesign 1st has been our trusted industrial design and mechanical engineering partner for over six years and they have proven themselves to be valuable, competent and committed to our success. They add value because they understand the tradeoffs between user value and cost, the need to balance both the business and product objectives, along with excellent knowledge of materials and manufacturing / tooling options.
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Mike Tettenborn VP Engineering, Caframo 
Right balance of art and engineering
Read Case StudyWe selected Design 1st because their designers and engineers demonstrated the right creativity and technical understanding. With their CAD and modelling tools they were able to address the numerous design challenges encountered with this type of product. The end result was an easy-to-install, powerful marine hatch fan – unlike any on the market.
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Kurt Francis Co-Founder, CTO, Molecule 
Deepest bench of technical talent
Read Case StudyI did a lot of due diligence on product development companies and Design 1st had the deepest bench for technical capability. They worked on such a broad range of products with successful commercialization. Design 1st’s early efforts in prototype development helped us move from a powder substrate into a commercial product for testing.
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John Lupton Director of Engineering, GeoSight 
Got up and running fast
Read Case StudyThe whole design was my idea and I had patents on them. The team’s main work was to solve the functionality issue of a piece of my design. On top of that, they helped identify one of our manufacturers.
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Didi Horn CTO, SkyX 
Exceeded Our Expectations
Read Case StudyThe Design 1st team exceeded our expectations and helped us deliver an exceptional product to the market. As a startup, we were working within a budget but expected the highest quality product. Design 1st identified the risks up front, had the vast network of partners to find the right components, and customized it to meet our unique needs.
End-to-End Mechanical Design Expertise to Power Your Product Innovation
Our mechanical engineering team tackles the most challenging technical problems—from concept to manufacturing—ensuring your product is robust, manufacturable, and market-ready. By addressing design challenges early and applying specialized expertise, we eliminate the technical roadblocks that typically delay product launches by months.
Ruggedized Engineering for Extreme Environments
Designing for harsh environments requires balancing material science, mechanical protection, and durability testing. Whether it’s underground mining equipment, exposed outdoor installations, or industrial automation, our designs withstand extreme conditions.
We identify environmental stressors early—temperature ranges, moisture ingress, impact scenarios—and select appropriate materials and sealing techniques. This systematic approach prevents field failures while maintaining reasonable manufacturing costs and timelines.
Video: Swabbot Collborative Robot Case study
Robotics and Automation System Design
Developing successful robotics requires expertise in motion control, mechanical kinematics, and system integration. Our team specializes in custom robotic solutions that solve complex industrial challenges.
We design collaborative robots, multi-axis positioning systems, and precision end effectors that deliver consistent results. From tank cleaning cobots to automated test equipment, we build mechanical systems that extend human capabilities while meeting strict performance requirements.
Strategic Reverse Engineering
Reverse engineering accelerates development by building upon existing mechanical solutions, reducing both cost and risk. Our process combines detailed physical examination, advanced scanning techniques, and systematic analysis to understand how successful products work.
We identify critical dimensions, material properties, and mechanical interactions to create enhanced designs with improved performance. This approach is particularly valuable for complex mechanisms, legacy part replacements, and competitive product analysis—delivering faster time-to-market while ensuring compatibility with existing systems.
Design for Manufacturing and Production Optimization
Manufacturing constraints directly impact product cost, quality, and production timelines. We identify optimal manufacturing processes early—injection molding, CNC machining, sheet metal forming—and design specifically for those methods.
Our mechanical engineers implement proper draft angles, wall thicknesses, and tolerance specifications from the concept phase. This systematic DFM approach prevents costly redesigns and tooling modifications, ensuring your product transitions smoothly from prototype to volume production with predictable costs and quality.
Video: VP Electronics Explains Designing Electronics for Manufacturing
The Only Team You Need to Solve Your Technical Mechanical Design Challenges
Design 1st’s in-house team of experts works as a single unit across design, engineering, software, and manufacturing to reduce risk, streamline development, and launch your connected device faster.
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Mechanical Engineering
Find creative mechanical solutions to technical challenges.
Mechanical Design Team
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Industrial Design
Transform your product concept into a refined manufacture-ready design.
Industrial Design Team
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Electronics Engineering
Add power, secure connectivity, and interaction control to your products.
Electronic Design Team
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Portfolio of Projects
Across every industry, our team excels at developing technically complex projects.
Fully Certified and Award-Winning
Our company and staff are professional engineers with multiple industry certifications.
Frequently Asked Questions
Do I Need to Sign an NDA First?
NDA’s ensure confidentiality for both parties during conversations. We provide a mutual NDA where the terms apply to both parties. Your organization may already have a mutual NDA that requires our signature. Instead, we handle signatures via email, online, or as circumstances require.
How Much Will My Project Cost?
Designing a new hardware product starts with defining one or two possible Concept Designs (CD), based on requirements and business targets. Our technical sales team create the first CD budget with the major activities. When the work starts, we capture key product requirements, research opportunities, and unknowns, then together with you, we determine the best solution to develop.
Our experienced development team will then facilitate and help you define the many product requirements, carry out the creative design and engineering process, examine manufacturing feasibility, and provide an ongoing estimate of the direct product cost as details are filled in and decisions on features, functions, parts, and quality are made. For a new product concept of moderate complexity, the CD design exploration and architecture definition stage takes 200+ hours. This timeline depends on many factors, including uncertainty about first users and buyers, the uniqueness of the design relative to products in the market, the number of custom components required for design and manufacturing, product safety requirements, manufacturing setup, and the amount of documentation required.
Professional, experienced Product Design and Engineering teams in North America charge $125 to $400 USD per hour. Our rates are competitive at the lower end of this scale. After a phone discussion on your needs, we will provide a detailed design budget for review and signature.
Call us: 1.877.235.1004 x229 or schedule a meeting with Ian Kayser, our VP of Sales, who will help answer questions.
Need help tackling tough technical challenges in your product development?
Design 1st integrates our knowledge and expertise with yours to bring your product idea to life.