Mechanical Design Services: From Concept to Manufacture

Some engineering projects begin with a complete technical specification, while others begin with a rough sketch, an unfinished model or an idea that still needs to be developed into a practical design. Thermic Edge provides mechanical design support for customers who need help moving from that initial starting point towards clear manufacturing information and production.

The Thermic Edge design engineering team can assist with mechanical design services including SolidWorks CAD modelling, individual part design, assembly design, manufacturing drawings, material selection, tolerancing and production planning. With more than 75 years of combined industry experience, the four-person design team has worked across a range of components, assemblies, materials and manufacturing methods.

What Do Mechanical Design Services Include?

Mechanical design can cover considerably more than the creation of a three-dimensional model. Depending on the project, Thermic Edge can provide support with the development of an individual component, a larger mechanical assembly, the preparation of manufacturing information or the planning of the route into production. The level of support can therefore be matched to the stage that the project has already reached and the information that is still required.

The published Thermic Edge mechanical design capabilities include:

• SolidWorks CAD modelling.
• Part design.
• Assembly design.
• Manufacturing drawings.
• Welded assembly drawings.
• Hand-built assembly drawings.
• Build instructions.
• Design specifications.
• Material selection.
• Tolerancing, including geometric tolerances.
• Failure mode analysis.
• Production planning.
• UK supplier recommendations.

From an Idea to a SolidWorks Model

A project does not need to begin with a finished CAD file. Thermic Edge states that its design team can work from a sketch, a concept or an idea that has not yet been modelled, developing the design in SolidWorks and preparing it for review. The starting point could be an individual component, a sheet metal part, a heated sample stage, a chamber feature or part of a larger furnace assembly.

Developing the concept in SolidWorks creates a defined three-dimensional model that can be reviewed before the project moves into detailed manufacturing drawings or production planning. This gives the customer and design team a clearer representation of the proposed component or assembly and provides a basis for the next stage of development.

From CAD to Manufacturing Drawings

Once a model has been developed and reviewed, the project may require a clear set of documents that can be used by suppliers, fabricators and production teams. Thermic Edge can produce detailed manufacturing drawings, welded assembly drawings, hand-built assembly drawings, build instructions and design specifications, allowing the information created during the design stage to be communicated in a practical format.

These drawings and supporting documents can define what needs to be manufactured, how the parts relate to one another and which requirements need to be met. Where required, Thermic Edge can also prepare engineering drawings in line with ISO 128.

From Design to Production

The Thermic Edge service can continue beyond the completion of a drawing. Whether a customer already has a completed design or the Thermic Edge team develops the design, the manufacturing route can also be reviewed as part of the project. Where required, Thermic Edge can provide a price and lead time for production, helping to connect the design stage with the next practical stage of manufacture.

Thermic Edge can also provide UK supplier recommendations. This may be useful where a project involves a specialist material, component or manufacturing method and an appropriate production route needs to be identified.

Individual Components and Larger Assemblies

Thermic Edge can support the design of both individual components and more involved mechanical assemblies. The design team has experience working on systems made up of hundreds of individual parts, with consideration given to fit, function, manufacture, handling and assembly. This allows the same design service to support projects ranging from a single component to a larger assembly containing numerous interconnected parts.

The published service covers machined parts, sheet metal parts, speciality fasteners, ceramic parts, CVD and PVD coated parts, plated parts and refractory metal components. The design process can also consider material choice, machining requirements, tolerances, supplier availability and how the completed design will be built and used.

Mechanical Design Connected to Thermic Edge Products

Thermic Edge’s mechanical design work is connected to the products and systems that the company manufactures. The Mechanical Design Services page identifies vacuum heaters, vacuum chambers, heater stages and vacuum furnaces among the areas in which the team has practical design experience.

These products can involve individual components, multiple-part assemblies and complete systems. The published Mechanical Design Services information states that factors including materials, heat, available space, fixings, access, manufacturing limits, assembly, handling and final use can all form part of the design process.

Vacuum Heater Design

Thermic Edge manufactures standard and bespoke vacuum heaters for a range of sample sizes, temperature ranges, chamber conditions and process requirements. For heater projects, the Thermic Edge design team works with customers to provide three-dimensional CAD models, detailed technical drawings and written specifications, creating a defined design package around the required heater configuration.

Standard Thermic Edge components and assemblies can be used where suitable, while bespoke heater designs are available where a standard design does not meet the application. Published heater options include water cooling, sample holders, flange or heater-stage mounting, rotation, sample transfer, RF or DC sample biasing, power supplies, temperature controllers and additional thermocouples.

Vacuum Chamber Design

Thermic Edge’s in-house design and engineering team can design and configure custom vacuum chambers and fabrications around the customer’s process, application, budget, available space and required configuration. Published capabilities include cylindrical, tube, spherical and box-type chambers, with stainless steel and aluminium construction options available.

Thermic Edge describes its chamber process as covering conception, design and drawing production, manufacture, fabrication, assembly, testing, inspection and aftermarket support. This gives customers access to support across the different stages of a custom chamber project rather than limiting the service to the initial design alone.

Heater Stage and Manipulation Design

Thermic Edge sample heater stages combine heating with a range of movement, positioning and process options. Heaters and samples can be mounted in different orientations, while available configurations can include sample rotation, heater rotation, sample transfer, sample positioning and heater positioning.

Published stage options also include linear travel, RF or DC sample biasing, water cooling, thermocouples and configurations for high vacuum, ultra-high vacuum, oxygen, air and corrosive environments. These systems demonstrate how several components and functions can be brought together within a single mechanical assembly.

Vacuum Furnace Design

Thermic Edge manufactures a range of vacuum furnaces for laboratory, research and production applications. The published range includes laboratory furnaces, benchtop furnaces, muffle furnaces, ALD systems and custom furnace solutions, giving the design team experience across both individual furnace components and larger integrated systems.

Thermic Edge also offers customisation involving pumps, hot zones, rotation, Z shift and RF or DC biasing. Custom furnace systems can be developed around specific process requirements, system layouts and vacuum heating applications.

Designing with Manufacture in Mind

Thermic Edge describes its mechanical design service as a route from concept to manufacture. The design stage can therefore include more than the shape or appearance of a component, with published considerations including materials, heat, available space, fixings, access, manufacturing limits, assembly, handling and how the finished item will perform in use.

The aim is to produce design information that is clear, accurate and suitable for the next stage of the project. By connecting the design work with manufacturing drawings, production planning and supplier recommendations, the service can support a more complete route from the original idea to the completed component or assembly.

Material Selection and Tolerancing

Material selection and tolerancing are listed among Thermic Edge’s mechanical design capabilities. The team can support projects involving machined materials, sheet metal, ceramic parts, coated parts, plated components and refractory metals, while supplier availability can also be considered during the design and production-planning process.

Tolerancing support can include geometric tolerances, and drawings can be prepared in line with ISO 128 where required. These services allow the manufacturing information to communicate the relevant dimensions, requirements and limits associated with the completed design.

Failure Mode Analysis

Failure mode analysis is also included within the mechanical design support offered by Thermic Edge. This gives customers the option to include structured consideration of potential failure modes as part of the wider design requirement, with the scope depending on the component, assembly and intended application.

Why Use One Team from Concept to Production?

Thermic Edge can support several stages of a project within one mechanical design service. The same team can help develop the original idea, create the SolidWorks model, prepare drawings and supporting documents, review the manufacturing route and provide production pricing and lead-time information.

This connects design and manufacture rather than treating them as entirely separate stages. It also means that the project can continue beyond the creation of the CAD model or drawing where additional support with production planning is required.

What Can Be Used as a Starting Point?

A mechanical design enquiry can begin at several different stages. Thermic Edge can discuss projects that start with a full technical specification, a rough sketch, an unfinished model, a concept that has not yet been modelled, a clear engineering idea or an existing completed design that requires further support.

The next stage can then be reviewed according to the current state of the project and the output that is required. This could involve creating a SolidWorks model, developing an assembly, preparing drawings, considering materials and tolerances or planning the route into production.

Frequently Asked Questions About Mechanical Design Services

Conclusion

Thermic Edge mechanical design services support customers who need help moving from an engineering idea towards manufacture. A project can begin with a complete specification, a sketch, an unfinished model, an existing design or a concept that has not yet been developed in CAD, with the design team providing support appropriate to the stage the project has reached.

The Thermic Edge team can provide SolidWorks modelling, part and assembly design, manufacturing drawings, material selection, tolerancing, failure mode analysis and production planning. Where required, the team can also review the manufacturing route, provide UK supplier recommendations and supply pricing and lead-time information for production.

This service is supported by direct experience designing and manufacturing vacuum heaters, vacuum chambers, heater stages and vacuum furnaces, providing practical mechanical design support from concept development through to manufacturing information and production planning.