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Engineering Simulation and Performance
Engineering Simulation and Performance
Engineering Simulation and Performance
Kyflo Design Mechanical prototype and engineering

Crafting Innovation and Elevating Mechanical Design

Mechanical engineering is the realm where movement meets innovation – simplifying challenging requirements into their purest form. From the subtle interlocking of gears to the satisfying tactile snap of plastic fittings.

Our lives are interwoven with the touch of mechanical engineering. It’s all about making the complex seem effortless. At Kyflo, we don’t just design products; we curate experiences that transcend desire into necessity.

Understanding Mechanical Engineering Services

Mechanical engineering is a calculated process that considers environmental factors, energy transformation, material dynamics, internal and external forces, and the manufacturing process.  It’s the silent yet pivotal contributor to crafting products that not only match your vision but surpass user expectations. If your product has moving components or requires mass manufacturing, a mechanical engineer is essential.

Kyflo mechanical expertise covers a range of services, including:

  • Mechanical design
  • Thermal/fluid dynamics
  • Tooling ready designs
  • Material science and flexing features
  • Tooling optimization & plastic flow
  • Sheet metal design
  • Additive manufacturing design
Conceptual Development: Illuminating Your Vision

In the exploratory phases, we delve into the art of bringing your innovative ideas to life. This journey involves an iterative and imaginative process aiming to visually encapsulate each unique feature within the overall design of your creation.

Kyflo Design Mechanical prototype and engineering Kyflo Design Mechanical prototype and engineering
Throwing everything at the wall to see what sticks

Albeit somewhat of a raw process, it serves as a powerful confluence of brilliant minds and ideas, fusing together to conjure the optimal solution for your product.

It’s an exploration of creativity to craft the best possible representation of your vision.

Reduce scope, dial in on the goal

Refined Concept

Building upon the earlier exploratory sketches and ideas, the refined stage consolidates all elements and design concepts into a comprehensive product sketch. This crucial phase focuses the goal, determines what is actually possible in the rhelm of technology and physics to achieve. It organizes thought and drives the business strategy. It’s a moment for reflective consideration, offering space for any final edits or adjustments before moving into the subsequent phases of CAD design, engineering, and prototyping.

Why a refining stage?

This stage enables quick adjustments, minimizing changes during CAD and engineering. It streamlines the process, ensuring a polished design, saving time, and maintaining alignment with your vision.

Reduce scope, dial in on the goal

Refined Concept

The journey from crafting a single prototype to manufacturing thousands of products is an adventure brimming with challenges. While creating one prototype might seem straightforward, scaling to mass production often reveals numerous unexpected complexities. At Kyflo, we understand this terrain well.

Why choose Kyflo?

Our track record boasts over 50 injection molding tools developed in the past decade. This wealth of experience instills a sense of trust and reliability in our clients. With our extensive design expertise, we spearhead the manufacturing of products at impressively low costs and high-performance standards, ensuring they endure the rigors of production, creating hundreds of thousands of parts aimed at long lasting performance. You can confidently place your trust in our proficiency and experience for a successful and cost-effective manufacturing journey.

3D Concept Design / CAD

Moving beyond the conceptual sketches, the CAD design phase is a transformative step. It involves harnessing cutting-edge 3D CAD software to construct the initial design of your product virtually. At Kyflo, we utilize industry leading, top of the line manufacturing-grade software such as Solidworks for mechanical engineering and Altium for electrical engineering for this crucial stage.

Where required, this may utilize contracted technical expertise for specialized areas of technology your product requires, ensuring a more streamlined journey through design and engineering only requiring specialized engineering muscle when needed.

This phase significantly eases the transition into the manufacturing phase, adding substantial value to the design process marking the pivotal transition from concept to a tangible, meticulously crafted product.

Examine & Refine

Simulation and Predictive Modeling

Our goal in this phase is to ensure the design is not only optimized for efficiency but also targets reliability within its intended environment. Through 3D virtual simulations, we aim to illuminate the limitations and enhance the design by testing it in various dynamic scenarios.

For instance, structural simulations enable us to determine the maximum load capacity, while material simulations identify weak points in plastic snap features which could be used to reduce manufacturing costs. Identifying these crucial mechanical elements is pivotal in crafting products that function flawlessly, ensuring reliable manufacturing processes, and delivering the ideal product version to your customers’ hands.

Iterate and Develop

Physical Prototyping

Kyflo Design Mechanical prototype and engineering

Hands-On Development

The CAD serves to verify the feasibility and functionality of the product design virtually. Moving to the prototyping phase, you’re presented with a tangible product, allowing a hands-on exploration of how it appears and operates in the real world. This stage is pivotal, as it offers the chance to assess the product’s physicality, understanding how customers interact with it. Not only does prototyping grant the opportunity to fine-tune and enhance the final design, but it also aids in minimizing costs and potential risks before transitioning to full-scale production. Our diverse prototyping methods, be it iterative, parallel, rapid, or streamlined, are meticulously crafted to ensure you’re well-prepared for user testing, investment pitches, crowdfunding, and every step in between.

While Kyflo does have a range of inhouse fabrication tools including Formlabs Form3 printers, capable of 25 & 100 micron  no-compromise prints, It is not always recommended to 3d print prototypes.

Sometimes, evaluating a products physical properties is critically important to the manufacturing process, how certain materials will perform under specific conditions, how parts mate, wear or interlock during assembly. These evaluations are better done using Kyflo’s various CNC prototyping vendors where parts are indistinguishable from final products.