Work

Projects and worked examples.

Real engagements, told without client specifics, and six worked examples of how analysis fits into a wider engineering investigation.

Projects

Some are one service. Some grew into many.

Integrated project

A production line for housing assemblies for meters

A Greek manufacturer bidding to supply housing assemblies to a multinational metering company. The support was built up step by step over the life of the project:

Consulting on the tender process
Support during the customer's audit
Quality and production procedures
Design and construction of the assembly line and its fixtures
All line automation: PLCs, HMIs, PCs, communications, databases, links to legacy and new machinery
Custom software to program and monitor the line

Industrial & production consulting Special & robotic automation, fixtures Custom software & IoT

Product engineering

A 3-axis gimbal, designed for serial moulding

Complete design and modelling of a 3-axis gimbal. The parts are engineered for serial production by injection moulding, with parallel variants for 3D-printed functional prototypes. FEA checks the structural integrity of the modelled assembly before tooling is committed.

Part & assembly design Design for manufacturing Structural analysis (FEA) 3D printing

CFD · Mechanical design

A hydroponic laboratory inside a shipping container

Responsibility for designing and optimising the climate and ventilation system, and for the mechanical design of everything inside the container. CFD shows how air moves between the cultivation racks, where it stagnates and where it short-circuits, so the layout and air distribution are corrected before construction.

Flow & thermal analysis (CFD) Part & assembly design

Product design · Consulting

A household-appliance maker bringing moulding in-house

Everything related to the company's injection-moulded parts: designing and redesigning bought-in parts, improving products with new moulded components such as a desktop grill, a moulded base and a handle, and management-level consulting on how its own injection moulding department should evolve and be set up.

Part & assembly design Design for manufacturing Injection mould construction supervision Industrial & production consulting

Robotic automation

A robotic cell linking two moulding machines

A 6-axis robot transfers parts between two injection moulding machines to produce overmoulded components. The work covered the cell design, the end-of-arm tooling, custom peripheral equipment and the control integration of the machines.

Special & robotic automation, fixtures Custom software & IoT

Worked examples

How FEA and CFD fit into a wider engineering investigation.

Typical situations, described the same way: the request, what a complete assessment has to consider, what simulation adds, and what decides the outcome.

Product redesign · Material optimisation

Reducing the material in a plastic housing

A manufacturer wants to use less material in a plastic housing. The question is not simply whether a thinner wall gives lower stress.

A complete assessment considers

The actual loading conditions
Mounting and assembly requirements
Manufacturing limitations
Warpage and dimensional stability
Local reinforcement options
Material properties
Required stiffness
Expected service conditions
The cost benefit of the change

What FEA adds

It compares alternative designs and shows where material can realistically be removed.

What decides

The numerical results together with the practical requirements of manufacturing and use.

Structural analysis (FEA) Design for manufacturing Part & assembly design

Product upgrade

An existing product for a higher load

A customer asks for an existing product with a higher load capacity. Redesigning the whole product is rarely the answer.

A complete assessment considers

Which components see the largest increase in load
Which areas may become critical
Whether the existing geometry remains adequate
Where reinforcement or a material change is needed
Secondary effects elsewhere in the assembly

What FEA adds

A detailed understanding of load paths and structural response.

What decides

Changes are targeted where they are needed, instead of redesigning everything.

Structural analysis (FEA) Part & assembly design

Failure investigation

Recurring failures in a pump or fluid-handling system

A manufacturer experiences repeated failures. A useful investigation starts from the operating conditions and the failure history, not from building a CFD model.

A complete assessment considers

Pump and system specifications
Flow rate, pressure, head and operating conditions
Pipework and system resistance
Installation and operating practices
Engineering calculations
Mechanical loads and structural implications where relevant

What CFD adds

Detail where the flow behaviour itself needs further investigation.

What decides

The engineering causes behind the failures, and which changes or further measurements are justified. Simulation is one possible tool within the investigation, not a substitute for understanding the system.

Flow & thermal analysis (CFD) Structural analysis (FEA) Industrial & production consulting

Plastic part design

Developing a reliable plastic snap-fit

A manufacturer needs a snap-fit for a new product. Several requirements interact.

A complete assessment considers

Assembly force
Retention force
Elastic deformation
Permanent deformation
Fatigue or repeated assembly
Material selection
Manufacturing feasibility
Tolerances
Temperature effects

What FEA adds

It compares alternative geometries and estimates deformation, stress and forces under defined assumptions.

What decides

Design iterations are settled before tooling, then confirmed by physical testing, often on printed prototypes.

Structural analysis (FEA) Design for manufacturing 3D printing

Ventilation · Thermal comfort

Natural ventilation instead of mechanical cooling

A building or product designer wants to use natural airflow and depend less on mechanical cooling.

CFD may help explore

Opening and window arrangements
Air inlet and outlet locations
Wind direction and velocity
Internal airflow patterns
Natural convection
Stagnant or poorly ventilated regions
The influence of geometry and thermal conditions

What CFD adds

It investigates defined scenarios and supports design decisions about openings and layout.

Limits

Real environmental conditions vary. CFD can investigate defined scenarios, but it cannot guarantee performance under every possible weather condition.

Flow & thermal analysis (CFD)

CFD and FEA combined

Wind loading on a small structure

A manufacturer is developing a small structure or product that will be exposed to wind.

An integrated study may involve

Defining the intended installation conditions
Establishing the relevant wind scenarios
Aerodynamic forces from CFD or appropriate engineering methods
Applying those loads to a structural model
Stresses, deformations and critical components
Comparison with the applicable design requirements

What simulation adds

Loads from the flow model feed the structural model, so the whole chain from wind to stress is traceable.

Limits

Where formal certification, regulatory compliance or public safety obligations apply, the analysis must be performed within the relevant standards and professional framework.

Flow & thermal analysis (CFD) Structural analysis (FEA)

Discuss your engineering problem.

Tell us what you are developing, changing or trying to fix. We first look at the engineering question, then say plainly what is worth doing: a calculation, a design review, a test, a simulation, or a combination.

Start a conversation +30 210 2207 582

Free first discussion Scoped to the question NDA on request