Mechanical Design

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Precision Modelling for
Real-World Solutions

At FormaSharp, mechanical design is more than just CAD—it’s the art and science of transforming ideas into functional, manufacturable products. With a foundation in nuclear engineering and years of experience in defense and industrial sectors, we bring a rigorous, performance-driven mindset to every project.

Whether you're a startup developing a new product or a manufacturer optimizing an existing system, we deliver designs that are robust, efficient, and ready for production.

Our capabilities

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Component & Assembly Design

FormaSharp specializes in creating detailed 3D CAD models for individual components and complex mechanical assemblies. Our designs ensure precise fit, functional performance, and manufacturability—reducing production costs and simplifying fabrication.

  • Parametric Modeling – Easily adjustable models for design iterations and customization

  • Tolerance Stack-Up Analysis – Ensures proper fit and function across all mating parts

  • Exploded Views & Assembly Instructions – Clear documentation for efficient assembly and maintenance

Mechanism Development

From linkages and gears to cams and actuators, we design mechanisms that deliver smooth, reliable motion.

  • Gear trains and transmission systems

  • Motion studies and optimization

  • Motion-capable assemblies

A close-up 3D rendering of a motorcycle suspension system with dual shock absorbers featuring black cylinders, orange coil springs, and yellow mounting plates.

Material & Fastener Selection

Group of metal bolts on a black background

Choosing the right materials and joining methods is critical. We work with clients to select appropriate materials and fastening techniques.

  • Metals, polymers, composites

  • Bolted, welded, and adhesive joints

  • Corrosion resistance and lifecycle planning

Industries We Serve

FormaSharp proudly supports a wide range of industries with tailored mechanical design solutions. From automotive and consumer products to aerospace, medical devices, and industrial machinery, our expertise spans sectors where precision, performance, and manufacturability matter most.

We also work with emerging fields like renewable energy, robotics, and agriculture—delivering designs that meet real-world challenges.

No matter your industry or idea, we’re ready to help.
If it moves, connects, supports, or performs, we can design it.

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Industries

Medical Devices

  • Precision components for surgical instruments, diagnostic equipment, and prosthetics

  • Focus on biocompatibility and sterilization

Agricultural Machinery

  • Durable mechanical designs for field equipment, irrigation systems, and harvesting tools

  • Emphasis on ruggedness, ease of maintenance, and cost-effective manufacturing

Renewable Energy

  • Structural components for wind turbines, solar panel mounts, and hydroelectric systems

  • Designed for environmental resilience, load-bearing performance, and long-term reliability

Robotics & Automation

  • Mechanical systems for robotic arms, conveyors, and automated machinery

  • Seamless integration with sensors, actuators, and control systems for intelligent motion

Packaging Equipment

  • Mechanisms for filling, sealing, labeling, and sorting

  • High-speed, precision motion systems

Construction & Infrastructure

  • Heavy-duty brackets, supports, and fixtures

  • Safety mechanisms and motion control

Consumer Electronics

  • Enclosures, mounts, and internal mechanical layouts

  • Thermal management and ergonomic design

HVAC & Plumbing Systems

  • Ducting, valves, and mechanical supports

  • Fluid flow optimization and thermal analysis

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Why FormaSharp?

  • Deep expertise with a design-first mindset

  • Seamless integration with prototyping and manufacturing workflows

  • Transparent communication and collaborative design process