Mechanical Design
At Orbis Electrica, our Mechanical Design services focus on creating robust, manufacturable, and thermally efficient structures that protect and support your electronics. From custom enclosures and mounting solutions to full system integration, our mechanical engineering expertise ensures your products withstand real-world conditions while maintaining performance and reliability.
We combine CAD modelling, thermal analysis, structural simulation, and materials engineering to deliver designs that are practical, cost-effective, and production-ready.
What We Offer
Our Mechanical Design capabilities include:
Enclosure Design
Custom housings for PCBs, wire harnesses, displays, and other components, engineered for protection, accessibility, and heat management.
Thermal & Structural Analysis
Detailed simulations of heat flow, airflow, mechanical stress, and vibration to ensure long-term reliability and prevent failures in harsh environments.
Mounting & Integration Solutions
Brackets, standoffs, fasteners, and supports designed for precise alignment, secure assembly, and ease of maintenance.
Material Selection & Finishes
Selection of metals, plastics, and composite materials optimised for strength, weight, durability, cost, and aesthetic requirements.
Prototyping & Rapid Iteration
3D-printed or CNC-machined prototypes for design verification, testing, and rapid feedback to refine functional and aesthetic elements.
Design for Manufacturability (DFM)
Ensuring designs are suitable for low- and high-volume production, reducing assembly errors, and lowering manufacturing costs.
Environmental Protection Features
IP-rated sealing, gaskets, and enclosures designed to protect electronics from dust, moisture, vibration, and temperature extremes.
Integration with Electronics & Harnesses
Mechanical layouts coordinated with PCB layouts and wire harnesses for seamless system assembly and improved maintainability.
Vibration & Shock Mitigation
Design features such as damping mounts, reinforced panels, and structural supports to protect sensitive electronics during transport or operational stress.
Custom Thermal Management Features
Inclusion of heat sinks, thermal pads, and ventilation paths to maintain electronics within optimal temperature ranges.
Modularity & Accessibility
Designs allow for modular assemblies and easy access for service, upgrade, or component replacement.
Key Benefits
Robust & Reliable Structures
Our mechanical designs protect internal components under vibration, shock, and harsh environmental conditions, ensuring reliable operation over the product lifecycle.
Optimised Thermal Performance
Thermal simulation, heat sinks, and airflow management maintain safe operating temperatures for electronics, extending component life and performance.
Custom Fit & Accessibility
Enclosures and assemblies are tailored to fit internal components precisely, with intuitive access points for maintenance or upgrades.
Material Efficiency & Weight Reduction
We engineer enclosures and supports to provide mechanical strength without excess weight, ideal for automotive, aerospace, portable, and energy applications.
Scalability for Production
Mechanical designs are optimised for both prototypes and high-volume production, ensuring consistency, repeatability, and cost-efficiency.
Design for Compliance
We integrate regulatory requirements, including safety, EMC/EMI shielding, and environmental standards, to ensure your product meets industry expectations.
Enhanced Durability
Mechanical solutions incorporate reinforced structures, strain reliefs, and protective coatings to improve lifespan in demanding environments.
Integrated System Design
Our mechanical engineers work closely with electronics, harness, and firmware teams to ensure all components integrate seamlessly for optimal system functionality.
Rapid Iteration & Testing
We create prototypes and simulate real-world conditions to identify and solve potential issues before mass production, reducing time-to-market risks.
Typical Applications
Mechanical Design services are critical wherever precision, durability, and integration are required:
- Industrial control panels and automation systems
- Renewable energy electronics and inverter enclosures
- Automotive and EV electronic modules
- Aerospace and defence components
- Medical and laboratory equipment
- Consumer electronics and IoT devices
- Outdoor and harsh-environment applications
- High-vibration and mobile systems
Customisation & Expertise
Orbis Electrica provides fully custom mechanical solutions designed to complement your electronics and harnesses:
3D CAD modeling, parametric design, and mechanical simulations
Thermal management and airflow optimization
Material selection for mechanical, thermal, and aesthetic requirements
Rapid prototyping and iterative design refinement
Integration planning for PCBs, wire harnesses, and enclosure assemblies
Vibration and shock mitigation strategies
Detailed manufacturing documentation, assembly guides, and quality checks
Our collaborative, detail-focused approach ensures mechanical designs not only protect your electronics but enhance overall system reliability, usability, manufacturability, and longevity.