Once all the major design concepts for your project are agreed upon, the next step is to define all of the details. This is where the real engineering comes in, and is the true bulk of the project.

Customer requirements and restrictions are essential to set as constraints to work within. Data needed from the customer typically include:

  • 3-Dimensional footprint (overall size)
  • Performance targets
  • Expected inputs (forces, power, etc.)
  • Operating environment (temperature, pressure, etc.)
  • Target cost

We then perform calculations to optimize every feature of every part, targeting the most efficient balance between performance, cost, and other factors. Engineering principles and professional software are used to calculate all pertinent variables (such as forces, stresses, power, efficiency, factors of safety).

Drawings and Engineering reports are available to you so that you know the “why” behind every detail.


Engineering technical specification drawing

Robust Engineering Process

Your product needs to work all the time, under all conditions. If you use Brainchild, you’ll get this. That’s because Brainchild uses a smart, systematic methodology to ensure that every design we release works under all conditions – “new or old, hot or cold“. We call it our Robust Engineering Process.

Design failures modes are often very difficult to predict.

For example, any deviation from nominal

  • Condition (new vs. used)
  • Temperature
  • Manufacturing tolerances
  • Environment

can cause unexpected problems in a design that are usually not discovered until it’s too late.

How can we catch these design problems before they make their way into physical parts? Shockingly, many engineering companies have no real way to detect design issues, beyond common sense and industry experience. While simple intuition can help engineers avoid common pitfalls (such as material fracture, etc.), human intuition is not perfect, and that’s why many engineering companies are constantly plagued with prototype design failure.

That’s why Brainchild doesn’t rely on simple intuition.

The Brainchild Robust Engineering Process is designed to take the guesswork out of failure mode prediction. How?

  • Identify all necessary sub-steps required to fulfill design goals
  • Ensure that each step is guaranteed to work under all possible conditions, considering as many variables as possible

Design studies can be thought of as “mental simulations” to catch difficult design issues, just like a filter is necessary to catch contaminants in water even if it “looks clean”. This is why design studies should incorporate as many factors as possible, even if they seem trivial.