Our Industrial Design Services

BP Nel Consulting delivers expert Industrial Design Services, backed by 29 years of experience. We now offer cutting-edge 3D printing services with our Bambu Labs P1S printer, enabling rapid prototyping to save you time and costs in product development. Our tailored design solutions cater to diverse industries, including leading automotive companies, showcasing our commitment to quality and reliability. We optimize designs for manufacturing processes such as injection molding, blow molding, die casting, vacuum forming, rotational molding, and sheet metal fabrication. Our goal is to reduce costs, enhance product quality, and accelerate your time to market.

3D Printing

Our 3D printing service, powered by the Bambu Labs P1S printer, delivers rapid prototyping to streamline your product development. We work with advanced materials like PA6 Glass Filled and Carbon Filled, TPU and more, ensuring durability and precision for your prototypes. This service saves you time and costs by eliminating the need for external prototyping. For inquiries, please Contact Us.

Aesthetic Design

Aesthetic design blends creativity and functionality to bring your vision to life. We deliver visually appealing, practical designs. Our focus is on creating designs that align with manufacturing feasibility. We refine existing concepts or create new ones. Your product will stand out while staying practical and cost-efficient.

Advanced 3D Modelling

Advanced 3D modeling transforms complex ideas into precise, manufacturable designs that meet industry standards. We create detailed and accurate 3D models tailored to your specifications. This service supports various industries, ensuring that products are production-ready and optimized for efficiency. From intricate parts to full assemblies, our designs meet exact specifications consistently. Moreover, our models align perfectly with manufacturing needs, facilitating a smooth transition from design to production. This approach enhances overall project success and product quality.

Industrial Design Services: Injection Molding

Design for Injection Molding optimizes products for efficient and cost-effective manufacturing processes. This approach minimizes material waste while reducing production challenges. Additionally, our industrial design services deliver high-quality products specifically tailored for injection molding applications. We focus on developing new components or refining existing ones to enhance performance. Ultimately, our goal is to create seamless, manufacturable designs that meet your specific needs and exceed industry standards.

Industrial Design Service: Blow Molding

The Blow Molding process manufactures hollow plastic parts such as bottles, tanks, and road barriers. We design innovative and manufacturable solutions specifically for hollow plastic products. This approach ensures material efficiency while maintaining structural integrity. Additionally, we optimize our industrial design services for smooth production processes and functional requirements. Our expertise includes critical factors like internal volume, wall thickness, label area, and camber needs. As a result, we deliver production-ready products that meet all specifications effectively.

Industrial Design Services: Rotational Molding

Rotational Molding creates durable, manufacturable designs for hollow, seamless products. This approach ensures even material distribution and maintains structural integrity throughout the production process. Furthermore, designs are optimized not only for efficient production but also for functional needs. Our industrial design services include critical aspects such as internal volume, wall thickness, and dry volume calculations. As a result, products consistently meet manufacturing requirements while achieving exceptional quality. Trust our expertise to enhance your rotational molding projects effectively.

Industrial Design Services: Vacuum Forming

The Design for Vacuum Forming service ensures your products are optimized for efficient and cost-effective production. We follow industry guidelines for draw depth and thickness differentiation throughout the design process. Additionally, we account for raw material sheet sizes to minimize waste, delivering practical, manufacturable designs tailored to your needs.

Industrial Design Services: High Pressure Die Castings

Our Design for High-Pressure Die Casting delivers robust, manufacturable designs optimized for precision and efficiency. Our design process ensures compliance with industry standards while addressing key factors such as draft angles and wall thickness. Additionally, material flow is optimized to enhance quality and reduce production challenges. From concept to completion, designs are tailored specifically to the die casting processes. This approach guarantees effective manufacturing and superior product performance.

Product Design for Sheetmetal fabrication

The design process for sheet metal fabrication ensures optimal results with a focus on practicality and cost-effectiveness. Critical factors like brake press limits, standard sheet sizes, and welding capabilities are carefully considered. Designs are both innovative and tailored for efficient fabrication.

Finite Element Analysis(FEA)

Our advanced FEA techniques enable us to simulate and analyze your products’ performance under various conditions. This process helps identify potential weaknesses and areas for improvement. By leveraging state-of-the-art software and methodologies, we provide detailed insights into stress distribution, thermal performance, and dynamic behavior. Consequently, you gain a comprehensive understanding of your product’s performance. With our FEA services, you can make informed decisions that reduce development costs. Ultimately, this enhances the reliability of your products before they reach the market.

Computational Fluid Dynamics(CFD)

Advanced simulation techniques analyze complex fluid interactions, helping visualize and predict real-world performance effectively. These applications span aerospace and fluid dynamics systems. CFD analysis provides valuable insights into airflow, pressure distribution, and thermal characteristics. Consequently, this expertise enhances efficiency and reduces energy consumption. Moreover, this support fosters confident innovation in your projects. Rely on these simulations to guide design decisions and improve overall performance.

Tool Design for Injection Molding

Tool design for injection molding involves a skilled team that combines creative methods with a strong understanding of materials. This approach leads to the creation of molds that operate efficiently and reduce production times.
Important factors such as part shape, material selection, and cooling systems are carefully considered. This ensures that molds produce high-quality parts consistently.
With a commitment to quality and attention to detail, products can be launched faster and more effectively.

Tool Design for Vacuum Forming

Tool design for vacuum forming requires expertise. Our team uses advanced techniques to create efficient and durable tools. These tools maximize production efficiency.
Key aspects include material selection, mold shape, and thermal management. This ensures optimal performance and precision in every project.
Whether you need prototypes or large-scale production tools, our solutions are tailored to meet your specific needs.

Welding Jig Design

We specialize in Welding Jig Design, offering custom solutions that enhance the efficiency and accuracy of your welding processes. Our experienced team collaborates closely with you to understand your specific requirements. As a result, we create jigs that ensure precise alignment and positioning of components during welding. We focus on factors such as ease of use, durability, and adaptability. This approach allows us to design jigs that streamline production workflows and improve overall quality. Whether you’re working on small-scale projects or large industrial applications, our innovative welding jig designs help you achieve consistent results. Ultimately, we aim to reduce production time and enhance your operational efficiency.

2D Manfacturing Drawings

We provide precise and detailed 2D Manufacturing Drawings that serve as essential blueprints for your production processes. Our skilled team creates comprehensive drawings that clearly communicate specifications, dimensions, and tolerances. This ensures that every aspect of your design is accurately represented. Additionally, whether you need drawings for machining, fabrication, or assembly, we tailor our services to meet your specific requirements and industry standards. With a strong focus on clarity and precision, our 2D manufacturing drawings facilitate seamless communication between design and production teams. As a result, we help minimize errors and streamline workflows effectively.

Project Management - Industrial Design Service

At BP Nel Consulting, we provide expert Project Management services for product development. With 29 years of experience as a BSc Mechanical Engineer, we leverage our extensive factory floor expertise.Moreover, we have collaborated closely with manufacturers in China, ensuring a comprehensive understanding of the production landscape. Each project phase, from initial concept to final production, is meticulously planned and executed.In addition, we emphasize effective communication, risk management, and strict adherence to timelines. This strategic focus drives your project toward successful completion. Furthermore, our deep understanding of engineering principles and manufacturing processes enables us to help you navigate challenges effectively. We optimize resources to achieve your product goals efficiently. Ultimately, you can trust us to manage your product development journey with professionalism and precision.

FAQ - Design for Manufacture

What is Design for Manufacture (DFM)?

DFM is the process of designing products, parts, or components to make them easier and more cost-effective to manufacture. It focuses on optimizing the design from the start to align with manufacturing capabilities, reducing potential issues like defects or inefficiencies. For instance, in industrial design services, DFM ensures that a product’s blueprint considers real-world production constraints, such as machine limitations or material behaviors. This is particularly relevant in the USA, where industries like automotive and electronics emphasize high-volume, efficient production. With 29 years of experience, BP Nel Consulting PTY Ltd can guide clients through this to avoid common pitfalls.

Why is DFM important in Industrial design?

DFM plays a vital role in ensuring products are not only innovative but also practical to produce at scale. It helps bridge the gap between creative design and feasible manufacturing, preventing expensive revisions later in development. In the USA context, where regulatory compliance and supply chain efficiency are key, DFM can lead to better quality control and faster market entry. It addresses both economic and environmental concerns by minimizing waste. For businesses seeking industrial design services, incorporating DFM from BP Nel Consulting PTY Ltd early can significantly enhance competitiveness.

What are the main principles of DFM?

The core principles revolve around simplicity, standardization, and optimization. This includes reducing the number of parts, selecting multi-functional components, maximizing tolerances where possible, and choosing materials that suit the manufacturing method. Other aspects involve facilitating assembly (manual or automated) and ensuring modularity for easier updates or repairs. These principles are applied across various USA-based manufacturing sectors to balance design intent with production realities.

How do you charge for your services?

Small project: We give a fixed price and approximate delivery date
Large projects: We give an hourly rate based on the technicallity of the work to be completed.

How long does it take to design something?

It depends on what your requirements are but let us use Electronics Covers for and IOT device as a sample.
Aesthetic Design: 8-16 hours
Detail Design for Injection Molding: 8-24 hours
2D Manufacturing Drawings: 4-8 hours
Realistic Renders: 8-16 hours
Animations: 8-32 hours

How much do we charge per hour?

We charge between $75/h and $150/h depending on the technicallity of the project.

How do we communicate with our clients?

We have a 50Mbps Simmetric Fibre installation on backup batteries to ensure we have full-time communication ability.
We use Google Meet, Zoom, Slack and Microsoft Teams to meet with our clients.

We prefer Slack since we also use Screen Cast videos explaining design concepts to our clients.

How does DFM reduce costs and improve efficiency?

By identifying and resolving design flaws early, DFM cuts down on material waste, labor hours, and rework. For example, simplifying geometries can enable faster machining or molding, while using off-the-shelf parts avoids custom tooling expenses. Efficiency gains come from higher yields and reduced downtime, with automated-friendly designs further streamlining processes. In industrial settings, this can translate to substantial savings, especially for high-volume runs common in USA manufacturing.

What are common mistakes in DFM?

Frequent errors include designing with overly tight tolerances that increase failure rates, overlooking how parts will assemble, or selecting materials incompatible with the process, leading to defects. Another issue is not consolidating parts, which raises complexity and costs. Avoiding these requires thorough reviews and collaboration, BP Nel Consulting PTY Ltd is helping USA-based clients achieve smoother production.

How long does a typical DFM process take?

The duration varies by project complexity: basic reviews might take hours, while detailed analyses for complex assemblies could span days to weeks, involving simulations and iterations. Starting early in the design phase shortens overall timelines. Experienced providers can expedite this through proven methodologies.