Mechanical Design Services

"Through measurements, analysis, engineering design, simulation and test, we optimise your designs"

Designing with the advantage: we’ve seen what goes wrong

Mechanical Integrity Consultants provides mechanical design support where vibration, shock, resonance, fatigue or structural response affects whether equipment survives. We are not offering low-cost drafting support.

A significant proportion of our work starts with underperforming or failed machinery and ends with verified, high-reliability design improvements — backed by physical measurement, advanced analysis, and repeat testing.

This matters because troubleshooting real-world failures teaches you what CAD models and ideal assumptions miss: actual boundary conditions, real excitation mechanisms, installation variability, and the small structural details that drive long-term reliability.

  • Structural Strength & Stress Validation: High-fidelity linear and non-linear stress analysis to ensure framework, process equipment, and mechanical assemblies withstand operational loads without yielding.

  • Fluid Dynamics & Flow Optimization (CFD): Simulating fluid flows, pressure drops, mixing behaviors, chemical containment, and thermal gradients—essential for pharmaceutical processing manifolds and piping networks.

  • Weight, Space, & Rigidity Optimization: Reducing mass while maintaining extreme rigidity. We optimize tight packaging envelopes and target high Young's modulus requirements for advanced or additive manufacturing.

  • Qualification & Code Compliance: Designing and validating components explicitly to pass demanding compliance audits and testing standards, including MIL-STD-810 and RTCA/DO-160 (vibration, shock, thermal, sand/dust, water, and altitude).

Formal Design Validation & Verification (V&V)

We close the loop between engineering theory and reality. Verification ensures the design meets mathematical baseline requirements and international standards (e.g., API 619, MIL-STD). Validation utilizes physical strain, modal, and vibration testing to prove that the mechanical change actively eliminates the root-cause failure mechanism (such as resonance or non-linear fatigue cracking) in the actual operating environment.

Chartered Engineering Leadership

Every project is directed by a dually qualified Chartered Mechanical Engineer (CEng MIMechE) and Chartered Acoustical Engineer (MIOA) with 30 years of professional industrial experience dating back to 1996.

Our foundation was built at an elite engineering consultancy led by university professors, operating out of a major fatigue and strength testing laboratory. Utilizing massive hydraulic actuators to simulate extreme operational loads, we physically tested, analyzed, and optimized the durability and reliability of high-consequence structures. This high-level forensic engineering background included:

  • Aerospace Structures: Designing and validating new engine cradles for DC-3 aircraft undergoing complex conversions from radial engines to modern turboprop turbines.

  • Heavy Industrial Infrastructure: Stress, fatigue, and reliability testing for mine shaft guide rails and high-capacity lift buckets handling heavy gold ore.

We bring that exact same high-consequence, lab-validated engineering mindset to your project today. We do not just provide drawings; we deliver peer-reviewed, audit-ready engineering validation backed by three decades of deep structural insight and advanced multiphysics simulation.

Explore our Finite Element Analysis (FEA) page - used extensively to validate and optimise mechanical designs for vibration, fatigue, strength, and structure-borne noise.

Case Study Examples & Capabilities

  • Pharmaceutical & Process Plant Engineering: Precision fluid dynamics (CFD) optimization and strength validation for processing components.

  • Aerospace & Defense Structural FEA: High-stiffness, weight-optimized component design and environmental ruggedization.

  • Falcon SPDB: Structural vibration and dynamic solutions.

  • Capacity Upgrades: Machine improvements to accept higher loads and increase maintenance intervals.

  • Packaging Constraints: Design for small spaces: space saving and weight saving.

  • Forensic Remediation: Fixing operational failure by design through forensic remediation.

What Are the Different Types of Mechanical Design Services?

  • New design: Creating a unique product or processing system from scratch

  • Adaptive & Development design: Engineering and improving existing equipment

  • Advanced Computational Fluid Dynamics (CFD)

  • Computer Aided Design (CAD)

When should Mechanical Integrity Consultants be involved?

Mechanical Integrity Consultants should be involved when equipment is cracking, vibrating, failing qualification tests, suffering fatigue damage, or showing reliability problems linked to vibration, shock or dynamic loading.

Can Mechanical Integrity Consultants support design before failure occurs?

Yes. Much of our experience comes from corrective action after failure, but the purpose of this service is to apply that knowledge earlier so that equipment is more vibration-resilient before it reaches test, commissioning or service.

How much do our mechanical design services cost?

We have competitive rates, and quotations are provided based on estimated time, complexity, and engineering resources required for your specific scope.

How We Engage & Next Steps

Contact us by phone or email to arrange an initial technical review. We can put an NDA in place immediately to safely examine your drawings, FEA/CFD models, or failure data. This scoping consultation is included prior to quotation so we can define the exact engineering resources required for your project.

What you can expect

Following the initial meeting, we work closely with your team to lock down precise mechanical design, and design requirements before any 3D CAD modeling or ANSYS validation commences.

How to contact us?

To find out more about our mechanical design services and simulation services, telephone or complete the form.

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