Mechanical Engineering – encore research

Product Design and Development

Preliminary concept sketches
- Rapid 3D CAD models
Industrial design
- For ergonomics, functionality and manufacturability
Design of parts and sub-assemblies
- Detailed mechanical design and material selection
Modeling, simulation and analysis
Prototype development
- 3D printing, CNC machining
Release to manufacture
- Complete manufacturing package
Design for manufacturing and assembly (DFMA)

Dynamic Systems

Design of precision motion control systems
Development of miniature electromechanical systems including solenoids, motors, actuators, couplings sensors and control systems
Design of lead screws and custom thread geometries for precise control and high-volume manufacturing
Design of micro-molded actuators for injection molding
Tolerance stack-up analysis
Stress, thermal, acoustic and vibration analysis
Finite Element Analysis (FEA) to analyze structural and thermal performance

Static Systems

Design of product enclosures
- Injection molded plastic enclosures
- Experience with wide variety of materials including plastics and rubber
- Stress, thermal and vibration analysis and optimization
- Design for ingress protection and EMI/EMC compliance
Design of complex jigs and fixtures
Development of sheet metal parts
- Progressive dies
Development of rubber parts
- Compression molded parts
- Cast parts
- Injection molded silicone
Design of springs
Design of screws and threads – UNS, UNS, Acme, Metric

Injection Molded Parts

Extensive experience with design of parts for injection molding
- Including insert molding and over-molding
- Mold-flow analysis
Specializing in micro-molded parts
- Extremely tight tolerances
- Optimized for performance and cost
Enclosures and housings
- For consumer products
- Designed for manufacturability
Global network of mold-making and molding partners for every need
Experience with a wide range of materials
- Material selection to meet product requirements – durability, weight, cost, safety
Fully equipped metrology lab for inspection and QC

Prototype Development

Engineering Analysis

Finite Element Analysis
DFMEA, PFMEA
Static and dynamic loading studies
Thermal analysis
Mold-flow analysis for injection molding
- Flow, pack and warp
Structural analysis
- Static and dynamic
- Linear/non-linear
- Fatigue and durability
Shock and vibration analysis
Acoustic analysis

Release to Manufacturing

Machine Shop and Tools

Fully equipped machine shop with HAAS 3-axis Vertical Machining Center
- Automatic Tool Changer
- Tool holders, cutting tools and measurement equipment
- Airconditioned facilities
- 3-shift operation
Tormach 3-axis Vertical Machining Center
3-axis CNC table-top milling machine
3D Printer (FDM)
BEMCO Environmental Test Chamber
High-precision watch-maker’s lathes
Heat-staking machine
Drill presses and other power hand-tools

Metrology Lab

Keyence Laser Measuring system (LJ V7060)
- Line laser with 0.4 micron accuracy
- THK X-Y motion table for precise 3D measurements
- Custom software for automation
Cambridge Instruments OptiCheck 3D measurement systems with 1-micron accuracy
Nikon Profile Projector
Mitutoyo calipers (Absolute Series) and micrometers (293 series)
High precision screw gauges, depth gauges (iGauging D69),bore gauges, pin gauges from Fowler & thickness gauges from Mitutoyo (7301).
Digital 3-axis angle protractors (DXL360S)
Height gauges
- Digital and analog from Mitutoyo (Absolute series)
- Automated height measurement system from Fowler ( Z_CAL300)
High accuracy surface plates
High-resolution microscopes from Leica (S4E), Zeiss, Bosch & Lomb (Stereo Zoom 4/5)
Celestron handheld microscope with up to 40X optical zoom with photo and video capture
Optical measurement systems from Omax (A355OU) with 0.01mm calibration reticle and advanced editing, processing and measurement features
High-speed video capture system (1000 FPS)
Torque measurement equipment from HIOS (HP 10)
High-accuracy force measurement tools