Overhead view of a workbench with prototypes, electronics and tools

TURNKEY PRODUCT DEVELOPMENT FOR START-UPS

ONE DIRECT CONTACT
CONCEPT TO PRODUCTION

One person.
The whole
product.

I personally develop the complete product: concept, mechanical engineering, electronics and programming, with FEA and CFD analysis when it helps answer the right questions. You work directly with me through every discipline, from the first idea to manufacture. No hand-offs. No hoops.

Explore the work
FROM MY WORKSHOP001 / SELF-INITIATED

CURIOSITY, BUILT.

A little obsessed
with how things move.

My Strandbeest. A walking mechanism,
designed and built in my own workshop.

SELECTED WORK / 01

Good ideas,
made tangible.

A selection of design, engineering and hands-on making. Each project starts with a problem worth solving.

Eight metre tall sculptural structure designed for 28 Years Later01 / 10

CONCEPT · STRUCTURAL DESIGN · ROBOTIC MACHINING

28 Years Later

An eight metre structure, designed from the ground up, machined on a KUKA robot, then painted and finished by hand.

Compact microscope positioning platform with integrated mechanical components02 / 10

MECHANICAL DESIGN · POSITIONING

Microscope positioning tool

A positioning tool for microscopes, designed around the optical path and lenses below the sample.

Illuminated chandelier assembled from many custom 3D printed translucent forms03 / 10

3D PRINTING · ELECTRONICS · ANIMATION

A chandelier in motion

Custom 3D printed “bottles” meet animated lighting, controlled by purpose-built circuit boards.

Handmade compact copper distillation column with a fine coiled tube04 / 10

COMPACT DESIGN · 3D PRINTING · HAND WORK

Compact distillation column

A space-conscious column developed for a project where every millimetre mattered, combining printed parts with careful hand fabrication.

Custom CNC controller pendant with a wooden enclosure, touchscreen and rotary control05 / 10

PRODUCT DESIGN · ELECTRONICS · CNC

Custom CNC pendant

A complete build: design, programming, electronics and a practical, workshop-ready enclosure.

A wooden test component being machined on a lathe06 / 10

PROTOTYPING · CNC · FIT DEVELOPMENT

Custom engine components

Representative components machined in bamboo to check geometry and fit before moving towards final parts for a demanding application.

Precision printed mould used to produce rounded square nitrile gaskets07 / 10

TOOLING · MATERIALS · ITERATION

A mould for custom seals

A purpose-made mould for producing rounded-square nitrile gaskets to suit a client project.

Intricately detailed sculptural forms, designed and fabricated as a series08 / 10

DESIGN · 3D PRINTING · HAND FINISHING

Sculptural forms

A detail-rich design brought into the physical world through a blend of digital fabrication and manual skill.

Custom vacuum automation setup with sensors, controllers and wiring09 / 10

AUTOMATION · SENSORS · CONTROL SYSTEMS

Vacuum system automation

The early stages of a complex vacuum automation system, bringing multiple sensors and controllers into one working setup.

Compact modified vacuum pump with custom brass rotary mechanism10 / 10

MECHANICAL REDESIGN · PRECISION · NOISE CONTROL

A quieter, more precise vacuum pump

An extensive modification of an inexpensive pump to meet a client’s need for a compact, powerful, precise and quiet system.

A first pass at the project selection. Images and descriptions are here for us to shape together.

THE SPACE BETWEEN IDEA & OBJECT

Sketch it.
Build it.
Make it better.

A product rarely gets there in one leap. I connect the design, the engineering and the making, so each version teaches us something useful about the next.

Here’s how we get there ↗
A SIMPLE PRINCIPLE

Get it off
the screen.
Onto the bench.

01 / FROM WHAT IF TO WHAT’S NEXT

Built in stages.
With you, throughout.

Start where you are.
Each stage ends in something tangible.
You decide when to take the next step.

Illustrative linkage drawing showing connected mechanical partsLINKAGE STUDY / FIG. 01MOTION → MATTERABCDILLUSTRATIVE PROCESS STUDY · Start with the question.

01 / DISCOVERY

A sketch is a perfectly good start.

A conversation about what you want to make, what exists already, and the problem worth solving. Bring a sketch, a rough prototype, or simply a question.

WHAT YOU TAKE AWAY

A clear direction

02 / THE WHOLE PRODUCT, ONE PERSON

Every discipline.
One conversation.

We work in short, rapid bursts of development and feedback, so decisions keep moving and each iteration informs the next. I can keep technical jargon out of the conversation or help you build your understanding as we go.

01

Product concept & design

You can send me napkin sketches or drawings, or we can talk it through over video. It is my job to work out what you are really after. Together, we explore the idea, who it is for, and what the product needs to do.

I develop early concepts and directions, then use your feedback to shape the form and experience. You might create a mood board, collect images for inspiration, or wave your hands around the artwork I share. Whatever helps you shape your vision.

Design is iterative: we work in short, rapid cycles, so you can respond at each step without long gaps. As mechanical, electronic, analysis or manufacturing decisions emerge, the concept may need to change. I can keep the technical jargon out of the conversation or take you into the detail and help you learn as we go.

Concept development / Industrial design / Ergonomics
02

Mechanical engineering

I develop the mechanisms, parts and assemblies that make the product work, resolving how components fit together and how the product will be used. Even a relatively simple product can have weak spots, parts prone to wear, or opportunities to reduce cost while keeping the functionality you need.

I can recommend suitable materials and manufacturing processes for the design. Those choices may send us back to earlier decisions: components might need to move, grow, change shape or be removed altogether.

CAD / Mechanisms / Materials / Manufacturing processes / Drawings
03

Electronics, firmware & programming

If the product needs electronics, I design them as part of the product rather than treating them as a separate process. Firmware provides the instructions that make the electronics tick.

Your product might need a screen, an app or a desktop program to control it. I can develop those too, and you can shape how they look and feel.

Electronics / PCB / Embedded firmware / User interface software
04

FEA & CFD analysis

Where it is useful, I use finite element analysis to explore how a design may respond to loads and computational fluid dynamics to study flow behaviour.

The analysis helps answer specific design questions and can guide the next iteration. I explain what the results mean for the product in clear, practical terms.

Finite element analysis / Computational fluid dynamics
05

Prototyping & testing

I make prototypes to check the design in the real world, learn from how the parts fit and behave, and identify what needs to change. Findings here can send us back to adjust an earlier design decision.

If you would like one, I can provide you with a working prototype to handle, evaluate or share with your team. We then use what we learn to plan the next short iteration.

FDM / SLA / CNC mill / Lathe / Testing
06

Design for manufacture

As the design matures, I prepare the models, drawings and technical information needed to move toward production, with attention to materials, tolerances, assembly and the chosen process.

Manufacturing feedback can reveal new constraints. I can work those findings back into the design and help carry it through to a production-ready package.

DFM / Drawings / Tooling feedback / Production support
THE WORKSHOP / TOOL NOTES
THINK.
MAKE.
REPEAT.
FDM & SLACNC MILLLATHEELECTRONICS

A PLACE FOR IDEAS TO BECOME OBJECTS.

03 / HELLO, I’M DANI.

A designer
with a workshop.

I work with start-ups at the beginning of something: an idea on paper, a mechanism that needs solving, or a product ready for its next iteration.

You talk directly to me about every part of the project. I personally develop the concept, mechanical design, electronics, programming and analysis, so the whole product stays connected from start to finish.

Having the tools here means I can learn by building. Print a part. Check the fit. Machine a revision. Keep moving.

Tell me what you’re working on ↗

COLLABORATION / VISUALISING COMPLEX IDEAS

From technical idea
to clear picture.

Across three challenge projects with Hugo Shelley, I helped turn complex concepts into illustrations and animations, grounded in a close understanding of the technical ideas.

01 / NASA TOURNAMENT LAB

Space Poop Challenge

Explore project
Space Poop Challenge project image

Working with Hugo Shelley, I modelled and visualised a complex astronaut waste-management concept. The illustrations needed to make an unusual, highly technical system understandable while the design was still changing.

Read the challenge story ↗
02 / NASA + BOEM

Next Generation Animal Tracking

Explore project
Next Generation Animal Tracking challenge image

For Team Gaia’s satellite animal-tracking idea, I translated the technical concept into clear illustrations and animation, with technical input to support the proposal. Team Gaia shared first place in the challenge.

Read NASA’s feature ↗
03 / NGA MAGQUEST

MagQuest

Explore project
MagQuest challenge image

I helped communicate Iota Technology’s compact satellite and magnetometer concept through technical visuals and animation. The work called for turning a novel, tightly integrated system into a picture people could quickly understand.

Visit MagQuest ↗

The three teams received awards across these challenge programmes. The expanded images are sourced from the original project and competition pages.

GOT SOMETHING IN MIND?

Let’s make
it real.

A napkin sketch. A stubborn mechanism.
A prototype that’s nearly there.
Tell me where you’re starting.