A cheap prototype removes risk before final material cost appears.
Wood mock-up for large geometry.
3D print for small parts.
Fast fit and handling checks.
BuildCheckCorrect
Slide 06 · Prototype
Integration and measurement
The prototype is checked with real hardware constraints, and measurements replace assumptions.
FitMounting and dimensions.
AccessAssembly and service paths.
CablesRouting and connector space.
Check actual dimensions against CAD.
Record deviations and root causes.
Keep photos, measurements, and issue list.
OutputMeasured deviations and correction list.
Slide 07 · Prototype
Correction gate
Findings go back into CAD, drawings, and prototype updates until geometry and integration are proven.
MeasureCorrect CADRebuild if needed
OKMove to real material.
Not OKReturn to correction loop.
Gate BGeometry proven
Fit, access, and constraints are confirmed.
Slide 08 · Release
Final sample
The validated design is manufactured in real material.
Supplier route is confirmed.
Final quote replaces the rough estimate.
Sample is assembled for testing.
validated CADsupplierfinal sample
Slide 09 · Release
Test and fix
The final sample is checked against the test plan. Findings are corrected and re-checked before release.
TestExecute agreed checks.
FixCorrect findings and re-check.
Gate CRelease evidence
No release without test result.
Slide 10 · Handover
Handover package
The client receives the sample and the data needed to use or reproduce it.
DesignModels and drawings.
EvidencePhotos and test report.
ProductionBOM, supplier notes, cost.
ResultControlled mechanical release, not an undocumented prototype.
Case C1 · Rapid validation prototype
Wooden prototype cabinet
The client needed a fast and low-cost way to validate equipment placement, cable routing, service clearances, and reserved footprint before moving to a metal build.
Client requestPrototype the layout, shelves, and routing paths first; measure real distances and gaps; reduce risk before metal fabrication.
Build conceptPine boards, plywood panels, and metal corner brackets, sized roughly like a work table, with open shelves for equipment and routing checks.
We designed a fast mock-up cabinet and defined the main equipment zones and routing logic.
The prototype was manufactured by our partner team and assembled by us in our office.
We used the wooden unit to place equipment, verify real clearances, and test cable paths before creating the metal version.
Customer benefitAbout 80% lower prototype cost compared with going directly to a metal version.
Lead timeAbout 4 days instead of roughly 17 days for a first metal iteration.
OutputMeasured layout, verified routing, clearer shelf areas, and better input for the next CAD / metal stage.
CAD tools: FreeCAD, Autodesk Fusion, and SOLIDWORKS according to concept, detailing, and release maturity.
Partner-made prototypeUsed by our team in-office for layout, routing, and clearance validation before the metal build.
Case C2 · Plastic enclosure validation
Diagnostic enclosure prototype
The customer was developing a housing for automotive diagnostic equipment used in an automated tester that verifies ECU integration and operational readiness in vehicle suspension systems.
Client requestProduce a rapid enclosure prototype so the team could place all electronics inside, confirm the internal fit, and check whether anything had been missed before the serial version.
Prototype focusA plastic enclosure with a bench-top form factor close to an oscilloscope, used to validate internal packaging, service space, and assembly feasibility.
We created the prototype enclosure and prepared it for internal placement and packaging checks.
The customer used it to install the electronics and found a design mistake before the production order.
The issue was corrected quickly, and the production mold was then ordered in the correct version.
Lead timeCase implemented in about 2 weeks.
Cost impactAvoided a mold-related mistake worth about 1,700 USD.
Customer benefitSafer transition to production, faster correction loop, and higher confidence before tooling.
CAD tools: FreeCAD, Autodesk Fusion, and SOLIDWORKS, depending on concept maturity, enclosure detailing, and release package needs.
Prototype enclosureUsed as a fit-check body for electronics packaging before final production tooling and mold order.
Case C3 · Final industrial cabinet
Bent aluminum cabinet
The case concerns a final cabinet for an industrial automation product. We worked on the full system packaging, created sketches and models, and developed the enclosure as a deep dark-gray painted aluminum housing produced by pressing and bending.
Client requestDevelop the final cabinet for an industrial automation device, define the system layout, and prepare a manufacturable aluminum enclosure with front-panel cutouts for the display, encoder, indicators, buttons, and selected interfaces.
Our roleOur team handled the design, system packaging, technical supervision, review, and testing. Manufacturing was performed by an external partner company.
We worked through the system composition, built sketches and 3D models, and defined the enclosure architecture and front-panel cutout logic.
We calculated and assembled the airflow model, selected ventilation power and vent placement, and refined the cabinet accordingly.
We selected the interface and HMI/HID concept, defined the screen, encoder, indicator, button, and interface openings, and provided technical supervision through production.
Some parts were prototyped on a 3D printer before the real aluminum version was produced by pressing and bending.
After production, we performed inspection, vibration testing, and assembled the equipment here on our side.
Material routePressed and bent aluminum parts, finished in gray paint.
CAD toolFreeCAD was used for the enclosure design and development work.
ResultFinal industrial cabinet with validated airflow, defined front-panel interface layout, tested mechanics, and controlled production follow-up.
Workflow summary: system packaging → sketches and 3D models → airflow calculations → interface/HMI definition → 3D-printed prototype parts → aluminum production → technical supervision → review, vibration test, and final assembly.
Dark-gray painted aluminum cabinetFinal enclosure concept for industrial automation, with front-panel cutouts for the display, encoder, indicators, buttons, and interface ports, plus our airflow work, supervision, testing, and final assembly.
Mechanical tools
CAD toolchain
Tool choice depends on task maturity: quick parametric model, prototype, assembly, production drawing, or manufacturing support.
FreeCAD
Fast parametric models
Early geometry, fixtures, simple assemblies, 3D-print/CNC export, and low-cost iteration.
Autodesk Fusion
Prototype to manufacturing
CAD/CAM/CAE workflow for concept refinement, manufacturability checks, and prototype preparation.
SOLIDWORKS
Production-oriented CAD
Parts, assemblies, drawings, release packages, and mechanical documentation for engineering review.
Contact
Send a short mechanical context
Useful inputs: target equipment, available space, hardware interfaces, loads, environment, expected result, drawings or photos, and timing.
