System Architecture & Risk Mapping

Where we define the machine and identify the "unknown unknowns."

  • Custom Machine Architecture: From-scratch concept generation and complex, CAD-based redesigns for OEMs.
  • Systems Integration: Mechanical integration of motion control, robotics, and automation components.
  • Risk & Opportunity Mapping: Identification of integration gaps, facility constraints, and technical blind spots.
  • Tooling & Fixturing: Design of custom assembly fixtures, tooling, and guarding systems.

Advanced Engineering & Validation
("Burn & Build")

Where we apply physics and rigorous design to “burn down” risk. This is the “heavy lifting” section.

Advanced Analysis & Simulation (FEA/CFD) - as applicable

  • Structural & Fatigue Analysis: Validating load cases for lifecycle durability.
  • Modal Analysis: Ensuring resonance frequencies do not interfere with machine operation.
  • Thermal & CFD: Fluid flow, HVAC systems, and conjugate heat transfer analysis for critical thermal management.
  • Machine Physics: Motor sizing inputs and detailed kinematic calculations.

Complex Mechanical Design

  • Precision Component Design: Machined components requiring tight tolerances.
  • Heavy Industry Design: Large-scale heavy-duty weldments and structural frames.
  • Plastics & Molding: Injection molding, over-molded parts, and cast part design.
  • Sheet Metal: Complex sheet metal assemblies and enclosures.
  • Additive Manufacturing: Design for industrial 3D printing and rapid manufacturing.

Prototype Management & Testing

  • Rapid Validation: Management of prototype builds to validate cycle times and handling (leveraging our network of trusted fabrication partners).
  • Assembly & Debug: Onsite support for startup, debug, and initial validation builds.

Execution & Documentation ("Handoff & Enable")

Where we ensure manufacturability and scalable data management.

Design for Manufacturing (DFM/DFMA)

  • Cost Optimization: Optimizing geometry and material selection to reduce COGS and assembly time.
  • Tolerance Analysis: Geometric Dimensioning and Tolerancing (GD&T) and stack-up analysis (RSS/Worst Case/Monte Carlo) to ensure fit and function.

Technical Documentation & Data Management

  • Production Packages: High-quality assembly drawings, BOM creation, and manufacturing prints.
  • Technical Writing: Machine manuals, work instructions, and maintenance guides.
  • CAD Management: Expertise in PDM/PLM systems (Windchill, Agile, Arena, Epicor) and developing company-wide CAD standards.
  • Interoperability: SolidWorks-to-Onshape transitions and library optimization.

Poindexter by Design | Top-notch Mechanical Engineering for Startups Developing Machinery

Copyright © 2026 Poindexter by Design LLC