Our Engineering Portfolio

Explore 500+ successful projects across automotive, aerospace, medical devices, and consumer products. See how we've helped clients save costs and accelerate time-to-market.

500+
Projects Completed
$2.5M+
Client Cost Savings
95%
Client Satisfaction
15+
Countries Served
Start Your Project

Featured Projects

Each project represents our commitment to delivering exceptional engineering solutions that help our clients achieve their goals efficiently and cost-effectively.

High-Performance Brake System Redesign
Automotive
Client
Performance Auto Parts Co.

High-Performance Brake System Redesign

8 weeks

Complete redesign of brake rotor and caliper assembly for improved performance and reduced manufacturing costs.

CAD Modeling
Manufacturing Documentation
Prototyping

Key Challenges

Reduce weight by 25% while maintaining strength
Improve heat dissipation efficiency

Our Solutions

Parametric CAD modeling for optimization
CFD analysis for heat dissipation

Project Results

40%
Cost Savings
6 months
Time Saved
27%
Weight Reduced
5/5
Client Rating
Engine Component Manufacturing Optimization
Automotive
Client
Midwest Engine Supply

Engine Component Manufacturing Optimization

6 weeks

Reverse engineering and optimization of engine components for improved manufacturability and performance.

Reverse Engineering
CAD Modeling
On-Site Consulting

Key Challenges

Reverse engineer obsolete parts
Improve manufacturing efficiency

Our Solutions

3D scanning and reverse engineering
Manufacturing process optimization

Project Results

35%
Cost Savings
4 months
Time Saved
60%
Waste Reduced
5/5
Client Rating
Advanced Lightweighting Design
Aerospace
Client
Aerospace Components LLC

Advanced Lightweighting Design

12 weeks

Lightweighting design for aerospace structural components while maintaining AS9100 compliance and safety requirements.

CAD Modeling
Manufacturing Documentation
Patent Assistance

Key Challenges

Achieve 50% weight reduction
Maintain structural integrity

Our Solutions

Topology optimization techniques
Advanced material selection

Project Results

30%
Cost Savings
8 months
Time Saved
52%
Weight Reduced
5/5
Client Rating
Precision Manufacturing Setup
Aerospace
Client
Precision Aerospace Systems

Precision Manufacturing Setup

10 weeks

Complete manufacturing setup for high-precision aerospace components with tight tolerance requirements.

On-Site Consulting
CNC Programming
Training

Key Challenges

Achieve ±0.001" tolerances
Setup new CNC manufacturing line

Our Solutions

Precision CNC programming
Custom fixture design

Project Results

25%
Cost Savings
3 months
Time Saved
99.5%
Quality Score
5/5
Client Rating
FDA-Compliant Medical Device Development
Medical Devices
Client
MedTech Innovations Inc.

FDA-Compliant Medical Device Development

16 weeks

Complete product development cycle for a novel medical device from concept to FDA 510(k) submission.

CAD Modeling
Patent Assistance
Manufacturing Documentation
3D Printing

Key Challenges

Meet FDA 510(k) requirements
Biocompatible material selection

Our Solutions

FDA-compliant design process
Biocompatible CAD modeling

Project Results

60%
Cost Savings
12 months
Time Saved
100%
FDA Approval
5/5
Client Rating
Surgical Instrument Redesign
Medical Devices
Client
Surgical Solutions Corp.

Surgical Instrument Redesign

14 weeks

Ergonomic redesign of surgical instruments for improved user experience and manufacturing efficiency.

CAD Modeling
Prototyping
User Testing
Manufacturing Documentation

Key Challenges

Improve surgeon ergonomics
Reduce manufacturing complexity

Our Solutions

Ergonomic analysis and testing
Design for manufacturing principles

Project Results

45%
Cost Savings
5 months
Time Saved
80%
Ergonomics
5/5
Client Rating
Consumer Product Market Launch
Consumer Products
Client
Innovative Home Solutions

Consumer Product Market Launch

12 weeks

End-to-end product development for a smart home device from concept to successful crowdfunding campaign.

CAD Modeling
High-Definition Rendering
Prototyping
Manufacturing Documentation

Key Challenges

Develop marketable product concept
Create compelling marketing materials

Our Solutions

Concept development and validation
Photorealistic renderings for marketing

Project Results

70%
Cost Savings
9 months
Time Saved
$150K raised
Funding Raised
5/5
Client Rating
Kitchen Appliance Redesign
Consumer Products
Client
Home Kitchen Innovations

Kitchen Appliance Redesign

10 weeks

Complete redesign of kitchen appliance for improved functionality, aesthetics, and manufacturing efficiency.

CAD Modeling
Industrial Design
Prototyping
Patent Assistance

Key Challenges

Improve user experience and safety
Enhance aesthetic appeal

Our Solutions

User-centered design approach
Aesthetic and functional optimization

Project Results

55%
Cost Savings
7 months
Time Saved
95%
User Rating
5/5
Client Rating

Industries We Serve

Our diverse portfolio spans multiple industries, each with unique challenges and requirements. Our cross-industry experience brings valuable insights to every project.

Automotive

50+

Projects Completed

Aerospace

50+

Projects Completed

Medical Devices

50+

Projects Completed

Consumer Products

50+

Projects Completed

Ready to Add Your Project to Our Portfolio?

Let DesignForge Engineering help you achieve similar results for your project. Get started with a free consultation to discuss your requirements and goals.