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Mechanical Design Consultancy

The creation of commercially successful products means intensive planning, bespoke development processes and the use of state-of-the-art tools and techniques. It also means combining innovative thinking with technical knowledge.

At Bluefrog Design our team are experienced innovators and industrial design engineers. We combine a wide experience of mechanical and electronic engineering, detail design and performance testing to find the best solution to build production-ready products while retaining the form and spirit of the original concept. Our team has extensive knowledge in various sectors, including the aerospace industry, showcasing our ability to provide design services for this industry.

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A leading mechanical design consultancy in the UK

Design Engineering Service

Mechanical Engineering

Mechanical Engineering is an essential activity in the design and development of a product. As the nuts and bolts of your design, this is where we assess whether each element will work efficiently and perform effectively. However, mechanical engineering is not an isolated activity in the design process – instead it must be considered at every stage during the product development journey through Computer Aided Design, Prototyping, Testing and Analysis to achieve outstanding results in the development process.

At Bluefrog Design, our team of product design consultants, integrate knowledge and experience in engineering, technology, manufacturing, materials and processes in every phase of the project. Our designs include complex and simple mechanisms and integrate mechanical and electronic solutions into fully functioning systems. Working collaboratively ensures that every skill set is used effectively to create market leading products. We utilize engineering analysis to ensure product performance, safety, and reliability.

Detail Design

Engineering design is the final step before entering the manufacturing phase of a project. It takes the output from design development and provides the precise information required for production; it contains the complete specification for every component that forms the product, including materials, geometry and supplier information for bought-in parts.

Our Detail Design takes into consideration the demands for manufacture and resolves and defines the final features of the product. The deliverables include all 3D CAD data, technical information, bill of materials and drawings that identify all individual components, sub-assembly and final assembly configurations. This allows one complete product to be delivered based on the best manufacturing options, processes and procedures to realise your project objectives.

Electronics Development

Our design team have experience in developing custom electronic based products. This, combined with our industrial design, allows your project to progress seamlessly across both disciplines, speeding the development programme. We research suitable systems, process specifications, components and needs to agree an electronic specification that also considers development and production costs.

We have extensive experience in handling product development projects for various clients, ensuring that all aspects of the project are managed efficiently.

In the early stages of the process, we create simplified electronic prototypes to prove the concept, before progressing with the design of alpha and beta electronics for manufacture. Where intensive solutions are required we partner with first-class electronics design and manufacturing companies, managing activities so that the product and electronics development evolve simultaneously.

Performance Testing

We use prototyping extensively to assess and explore the performance of a product in development and to mitigate risk. By doing so we check the results of our analysis and detailed design, building our understanding and driving a product’s evolution. Performance testing also plays a vital part at the pre-production phase prior to full-scale manufacture, confirming that first-off production samples function as intended.

Finite element analysis is also utilized in performance testing to optimize and verify mechanical designs through simulation and FEA.

Our testing facilities are equipped for a wide range of functional testing and performance analysis, including environmental test chambers, force and torque measurement, precision balances and CMM touch probe and vision-based 3D HD laser scanning systems. When you need to test your design, we are fully equipped to give you the confidence that your product really works.

Reverse Engineering

The evolution of a product relies on innovation. Our role is to provide mechanical design services that take an existing product and refine and improve that design. Reverse engineering is an effective tool that allows us to explore a product through detailed analysis to gain a valuable understanding of its makeup.

By learning about the structure of a product, using a variety of techniques, vision and measurement-based technologies, we can discover the hidden details of its manufacture and function. We can then innovate the design, improving performance, enhancing usability, and reducing manufacturing costs. At Bluefrog Design we use reverse engineering to push the product design and engineering programme forward.

View more of our Product Development Services

If you would like to hear more on how we can improve the quality of your products or help with your product development, please contact Bluefrog Design at

FAQ’s on Mechanical Engineering

What is the job of a mechanical designer?

A mechanical designer’s role is to conceptualise, design, and detail mechanical systems or components, leveraging engineering principles. They utilise CAD tools for drafting and simulations, ensuring designs are efficient, manufacturable, and meet set specifications. Their work intersects with material science, manufacturing processes, and product lifecycle, aiming for optimal functionality and cost-effectiveness.

What are the basics of mechanical design?

Mechanical design fundamentals encompass the conceptualisation and detailing of mechanical components/systems. Core elements include understanding material properties, adhering to engineering principles, and optimizing for manufacturability and functionality. Utilising CAD tools for drafting and simulations is pivotal. The design process also involves considerations for stress, strain, fluid dynamics, and thermodynamics, ensuring components’ durability, efficiency, and cost-effectiveness.

What are the three types of mechanical design?

Mechanical design is typically categorized into three primary types: 1) Machine Design, focusing on creating components of machines ensuring functionality and longevity; 2) Tool Design, dedicated to creating specialised tools facilitating manufacturing processes; and 3) Product Design, oriented towards crafting consumer goods considering aesthetics, ergonomics, and functionality. Each type demands a unique skill set but collectively relies on fundamental mechanical principles and design methodologies.

What is the difference between mechanical design and engineering?

Mechanical design and mechanical engineering, while interconnected, differ in focus. Mechanical design emphasises the conceptualisation and detailed creation of products, tools, or systems, emphasising aesthetics, ergonomics, and functionality. In contrast, mechanical engineering provides a broader view, encompassing the application of scientific and mathematical principles to design, analyse, manufacture, and maintain mechanical systems.

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