Ben N.

I help companies turn product concepts and prototypes into production-ready products for injection molding, electronic enclosures and sheet metal fabrication.

With 30+ years of product development and Design for Manufacturing (DFM) experience, my focus is not simply creating CAD that looks correct. I design products around how they will actually be tooled, manufactured, assembled and produced reliably.

REAL MANUFACTURING EXPERIENCE

My experience includes products that have progressed well beyond the prototype stage:

• 100,000+ units manufactured - high-volume injection molded electrical products developed from concept through DFM, tooling interaction, first-off-tool changes and production.

• 5,000+ units manufactured - commercial electronic enclosure where I completed the product design, injection molding DFM and complete injection mold tool design.

• Commercial sheet metal products still in production - complete fabricated mechanical products involving sheet metal DFM, mechanisms, FEA, welding, BOMs, DXF files and manufacturing drawings.

• Approximately 65 electrical products developed for one long-term manufacturing client.

• Approximately 20 fabricated mechanical products developed for an international access-control manufacturer.

MY CORE SERVICES

Injection Molding & Plastic Product Design
• Injection molded product development
• Plastic part design
• Injection molding DFM
• Wall thickness, ribs, bosses and draft
• Undercut and tooling-risk reduction
• Design for Assembly (DFA)
• Prototype-to-production development
• First-off-tool / T1 design corrections

Electronic Enclosure Design
• PCB enclosure design
• Internal component packaging
• Connector, button, LED and display integration
• Injection molded electronic housings
• Fastening and assembly strategy
• Production-ready enclosure CAD

Sheet Metal Product Design
• Sheet metal DFM
• Fabricated mechanical products
• Welded assemblies
• Mechanism development
• FEA
• Weight and structural optimisation
• Manufacturing drawings
• BOMs, DXFs and welding documentation