Medical Treatment Chair
This medical chair redesign was driven by the dual challenge of cutting costs while significantly increasing versatility and safety (up to 300 kg capacity). As the lead mechanical engineer, my process focused on structural optimisation using FEA to slim down the column and simplify the design, achieving a 17% manufacturing cost reduction. Key prototyping successes included validating the low-profile actuator mount for patient access and perfecting the robust, easily assembled pivoting mechanisms, resulting in a single, high-capacity chair that is both cost-effective and a superior performer in the modern hospital environment.
Rugged Recreational Vehicle
Stockman ROVER
We partnered with Stockman Products to push the Rover caravan beyond expectation, focusing on both performance and production efficiency. This massive project included redesigning the chassis for independent suspension and maximized storage, engineering a revolutionary flexible door sealing system for superior dust protection, and integrating utilities like the water tank and electrical systems for a cleaner look and easier maintenance. We also introduced specialized assembly jigs and reworked the electrical switchboard to improve production quality and worker safety. The result is a more rugged, efficient, and exceptionally high-quality off-road masterpiece.
Some Other
Projects
We hope you like all of our projects shown here, as much as we've liked being a part of them.
Fire and Feast
Fire and Feast is a project developed in house from frustrations whilst enjoying the great outdoors. We set out to design something rugged and versatile, something to cook with easily and something to contain a warm camp fire. See our equipment pages for more information. www.FIREANDFEAST.co
Rear canopy optimisation
In this project I was given the task to optimise the rear working canopy. With this opportunity we also created a format that was easily edited for quickly creating bespoke canopies. These canopies could be flat packed, shipped and assembled on site. Click this link to find out more details.
Blueprint for Extreme-Duty Storage
Off-road reliability is a direct result of meticulous design, and the development of these heavy-duty storage drawers perfectly showcases our engineering process. The challenge was building a solution that was resilient yet customizable, which we solved by demanding exceptionally tight tolerances using CNC steel fabrication to eliminate road noise and wear. Every feature, from the robust whale tail locks to the functional half-locking mechanism and weatherproof sealing, was engineered specifically for extreme environments and vehicle integration. Read the full case study to understand the detailed problem-solving and DFM planning that makes this solution—and our consultancy service—uniquely effective for any product challenge.
Ute Slide Development
Solving the heavy-load access problem required specialized mechanical design, focusing on durability and precision. We created this Ute slide by blending high-grade mild steel and lightweight aluminium, using CNC fabrication to achieve flawless operation and reliable safety features like the lock-in/lock-out mechanism. Read the full case study to see how our engineering expertise transforms frustrating problems into robust, high-value product solutions.
