Engineering Discipline
Mechanical Designs Engineered for Manufacturability, Maintainability, and Operational Safety
FERSMEK mechanical engineers design custom machines, fixtures, and structures from concept to commissioning-ready hardware. ISO 13849 safety integration and AI-assisted design review are standard — not optional extras.
What We Do
Every FERSMEK mechanical project starts with a functional specification — not a catalogue. Our engineers design machines and structures that fit your specific process, space, and safety requirements. We use Fusion360 for 3D modeling, FEA for structural validation, and AI-assisted tools to catch design issues before fabrication begins.
Because FERSMEK also handles electrical and software integration, mechanical designs are developed with full awareness of where cables route, how sensors mount, and how operators interact with the machine day-to-day. The result is hardware that is easier to build, easier to maintain, and easier to modify as production requirements evolve.
Core Capabilities
Custom Machine Design
Complete mechanical system design from concept sketch to fabrication-ready drawings using Fusion360. We model the full 3D assembly — frame, actuation, fixturing, guarding, and access panels — so interference, ergonomics, and maintenance access are resolved before the first cut. Client review at concept and detail design stages keeps the design aligned with your requirements throughout.
Fixture & Jig Engineering
Precision fixtures for assembly, welding, and inspection — designed for repeatability, ease of loading, and operator safety. Datum strategy, clamp sequence, and part presentation are defined from the dimensional drawing before fixture design begins. GD&T callouts are verified through tolerance stack analysis to confirm the fixture can achieve the required positional accuracy.
DFM & Tolerance Analysis
Design-for-manufacturability review and tolerance stack-up analysis to reduce rework and ensure first-article success. We evaluate every assembly for machinability, weldability, and assembly sequence — flagging parts that will be difficult or expensive to produce before fabrication is committed. Statistical tolerance analysis identifies the critical chains that drive overall assembly variation.
Structural Analysis
FEA-based structural review for frames, mounting structures, and load-bearing components before fabrication. We run static and modal analyses to verify deflection, stress, and natural frequency against operating load cases — so structural failures are caught in the model, not on the machine. FEA reports are delivered as part of the design documentation package.
ISO 13849 Safety Integration
Safety-rated guarding, light curtains, interlock systems, and emergency stops designed in from the concept phase — not retrofitted. We produce the risk assessment, define required Performance Level for each safety function, and design the mechanical and electrical safety architecture to meet it. Safety integration from day one is cheaper and more effective than adding it after the design is complete.
AI-Assisted Design Review
Automated design checks for interference, accessibility, and standard compliance — reducing revision cycles before any metal is cut. We use AI-assisted tools to scan completed 3D models for common design errors: hard-to-reach fasteners, missing maintenance access, inconsistent hole patterns, and standard component substitutions. Issues caught at this stage cost a fraction of what they cost in fabrication or commissioning.
Technology Stack
Our Design Process
Requirements Workshop
Define functional requirements, space constraints, cycle time targets, and safety category.
Concept Design
2-3 mechanical concept options with trade-off analysis. Client approval before detail design begins.
Detail Design & AI Review
Full 3D model, drawings, and BOM. Automated interference and compliance checks before client sign-off.
Fabrication Coordination
FERSMEK manages fabrication with qualified local suppliers. Dimensional inspection before assembly.
Assembly & FAT
In-house mechanical assembly and factory acceptance test. Commissioning support at your site.
Industries This Service Supports
Custom Automotive Welding Fixture — Body Panel Sub-Assembly Jig
A Tier-1 automotive supplier needed a body panel sub-assembly welding fixture for a new model introduction with a 14-week delivery requirement. FERSMEK began with the customer's GD&T drawing and fixture design standards, developed the datum strategy and clamp layout in a 2-day workshop, and produced a full 3D fixture model in Fusion360 within 10 days. AI-assisted interference checking identified four clamp arm conflicts at the design stage — before fabrication began. The fixture was fabricated locally under FERSMEK supervision, dimensionally inspected against a 3D scan, and delivered within schedule. The first-article inspection report was submitted to the customer before the fixture was commissioned in production.
Frequently Asked Questions
Related Services
Start with a Mechanical Engineering Assessment
Bring your concept, sketch, or specification. Our engineers will review the mechanical requirements and propose an approach within a week.