Precision Mechanical Engineering & Equipment Design
Detailed Design, Structural Analysis, and Retrofit Solutions for Heavy Industry.
Machinery doesn't fail on paper—it fails in the field. We deliver rigorous mechanical design, detailing, and analysis to ensure your equipment fits, functions, and lasts.
The High Cost of Mechanical Failure & Poor Integration
In a high-output environment, the transition from a digital concept to a physical asset is where the greatest risks live.
When engineering is treated as an afterthought, the consequences are expensive and immediate.
New equipment arrives on the floor only for your team to realize it doesn't fit within the existing steelwork or creates a permanent maintenance nightmare.
Your legacy conveyor systems are suffering from structural fatigue, yet the original drawings are long gone, leaving you unable to manufacture critical replacement parts.
Standard equipment from "Black Box" vendors fails prematurely because it wasn't rated for your specific load cases, duty cycles, or environmental stressors.
Uncalculated material fatigue and tolerance stack-up lead to chronic interference and clashing that halts production lines.
Engineering the Physical Asset
At Design Systems, Inc., our mechanical engineering service acts as the vital bridge between a conceptual process and a fabricated reality.
We don't just provide "ideas"; we provide the technical detailing and validation required for manufacturing success.
As a vendor-agnostic consultancy, our loyalty is to your operational uptime, not a specific brand of motor or bearing. We design the optimal mechanical solution for your specific application.
Whether you are dealing with a broken machine or a blank-slate project, we utilize advanced scanning to reverse-engineer aging assets and engineer superior, high-durability replacements that outperform the originals.
Core Mechanical Capabilities
Conveyor & Machine Design
We specialize in the physical engineering of moving parts, including drive sizing, kinematics, and carrier detailing.
Our team designs the heavy-duty structural steel, weldments, and support systems required to keep your lines moving.
Every design adheres to strict CEMA standards to ensure your system can handle increased payloads without compromising safety or longevity.
Tooling & Equipment Design
Our engineers develop custom end-of-arm tooling (EOAT), precision jigs, and ergonomic lift assists tailored to your specific assembly needs.
By applying rigorous GD&T (Geometric Dimensioning and Tolerancing) and fixture tolerance standards, we ensure that even the most complex parts, like EV battery packs, are handled with absolute precision and operator safety.
Health Assessment & Forensic Engineering
When a drive shaft shears or a truss bows, you need to know why.
We perform Root Cause Analysis (RCA) and Finite Element Analysis (FEA) to identify wear patterns and stress points.
Our equipment health assessments determine if your existing infrastructure is strong enough for new loads or if fatigue has rendered it a liability.
Spatial Integration & Layouts
We eliminate the "will it fit" gamble through 3D facility layouts and high-fidelity clash detection.
By converting point cloud data into CAD models, we verify as-built conditions to ensure new machinery fits perfectly between building columns, HVAC ducts, and existing utility lines.
Our installation drawings provide a clear roadmap for a seamless floor integration.
Why Clients Trust DSI with Heavy Machinery
Precision is our baseline.
While others provide rough estimates, DSI works within exact tolerances to ensure that every bolt hole aligns and every load is supported.
We utilize industry-leading CAD and CAE platforms, including Catia, NX, SolidWorks, and Inventor, to maintain full interoperability with your internal engineering standards.
Most importantly, we design for manufacturability.
Our decades of experience in the field mean we never hand over a design that cannot be realistically machined, welded, or maintained by your tradespeople.