We Build the Machines You Can’t Buy Off the Shelf.

From robotic food makelines to complex aerospace assembly fixtures, we solve the "unsolvable" mechanical challenges for the world's most innovative companies.

Disclaimer: Due to the proprietary nature of our work, many of our projects are confidential. The case studies below represent a cross-section of our capabilities.

Featured Project:

The Robotic Makeline: Hyphen (Food Robotics / Automation)

The Challenge:

Hyphen possessed rough prototypes for an automated salad-making line faced significant mechanical hurdles regarding reliability, cycle time, and cost. They needed to move from “prototype” to a scalable, NSF-certified machine capable of surviving real-world, demanding kitchen environments.

The Solution (The De-Risked Method):

Burn & Build: We executed several multi-month engineering sprints with rapid prototyping to overhaul every mechanical subsystem and mechanism, evaluate cooling and refrigeration performance, and convert proven functional designs into cost-effective DFM’d equivalents.

Compliance: We managed the mechanical documentation and design adjustments required for strict NSF certification.

The Results:

Fully functional makelines that were successfully piloted in stores, achieving business targets and securing a path for massive scale.

Advanced Manufacturing & Assembly

Project: The Multi-Axis Hypercar Assembly Fixtures

Industry: High-Performance Automotive (Confidential Client)

Problem: A manufacturer of multi-million dollar hypercars relied on risky manual assembly processes for critical components.
Solution: Developed complex, precision manufacturing assembly fixtures to secure the most difficult parts of the build.
Outcome: Repeatable, efficient assembly that minimized risk to expensive components.

Project: Satellite Array Joining Cell

Industry: Aerospace (Confidential Client)

Problem: Need for a semi-automated line to join massive solar panel arrays for satellite buses. Manual joining was inefficient and ergonomically dangerous.
Solution: Designed a “from-scratch” industrial sewing cell using sensor-driven pneumatics to support the massive work surface.
Outcome: A successful work cell that enabled accurate, repeatable joining of flight-critical hardware.

Heavy Industry & Structural Analysis

Project: 300-Foot Vessel Modification

Client: Space Perspective (Stratospheric Ballooning)

Problem: The client needed to modify a 300-foot ship to support multi-ton equipment loading on deck, requiring Coast Guard validation.
Solution: Created a detailed, FEA-ready model of the ship structure and designed reinforcement concepts. We worked directly with ABS and the Coast Guard to validate the analysis.
Outcome: Validated designs that allowed for safe, confident equipment handling at sea.

Project: Safety Retrofit for Heavy Material Handling

Client: Saeger Machine

- Problem: Operators were exposed to hazards when racking extremely large, heavy rolls of material on a conveyor system.
- Solution: Developed a specialized conveyor section capable of easily raising and lowering roll rack guards.
- Outcome: A robust, easy-to-implement system that drastically reduced operator hazard.

Automation & Inspection

Project: The "Blue Sky" Crate Assembler

Industry: Consumer Goods Manufacturing (Confidential Client)

Problem: A company was leaving money on the table because of the manual production of high-volume, aesthetically critical wooden crates.
Solution: Developed a novel, custom machine from scratch to automate the entire assembly process using a parallel-work approach (processing multiple crates simultaneously).
Outcome: A complete machine package including guarding, sensors, and pneumatics that exceeded production targets.

Project: Robotic Glass Inspection Cell

Industry: Consumer Electronics Test & Inspection (Confidential Client)

Problem: A high-tech manufacturer needed a complete machine to inspect consumer electronics for microscopic defects.
Solution: Designed the framework, shielding, camera mounting, and robotic subsystems to hold, move, and evaluate the target.
Outcome: Successful machine build and deployment, achieving performance and cost targets on a tight timeline.

Your Secrets Are Safe With Us.

In the world of custom machine design, Intellectual Property is your most valuable asset. We treat it that way.

You Own the IP: Unlike firms that try to retain ownership of design files, our policy is simple: Upon project completion and payment, every CAD model, drawing, and calculation belongs 100% to you.
NDA Standard: We routinely operate under strict Non-Disclosure Agreements with high-profile OEMs and stealth startups. We are happy to sign your standard NDA prior to our first consultation.
Discretion is a Feature: You will notice many projects on this page are listed without photos or client names. That is by design. We prioritize protecting our clients’ competitive advantage over filling our portfolio. When you hire us, you can trust that your “secret sauce” stays secret.

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