Mechanical engineering consultancy · Sydney

Designs that work
not just in CAD —
in production
and in the field

Mechanical engineering for products where failure is expensive — structural validation, DFM, and engineering judgement before you commit to prototypes, tooling, or production.

16+ years experience
Mobility · bicycle · structural hardware
Good Design Award winner
Concept to production delivery
Sydney · clients globally
Design review
Identify failure modes before they become costly
Structural validation and DFM review before prototype or tooling commitment — failure modes, simplification opportunities, and risk surfaced early.
Product development
From concept to manufacturable hardware
Full lifecycle engineering — concept, CAD, structural analysis, prototyping, DFM, and supply chain. Enter at any stage.
Fractional engineering
An experienced product engineer in your corner as your hardware evolves
Ongoing access to specialist mechanical engineering — structured to your development cadence.
James Carchrie
James Carchrie — MEng
Mechanical engineer with 16+ years delivering production hardware across light electric vehicles, bicycle components, and structurally demanding consumer products. Founder of Carchrie Engineering.

Typical engagement points

Clients typically engage us when...

These are the moments where the cost of getting the engineering wrong is highest — and where our judgment adds the most value.

Have an idea but don't know where to start
We can map a path from first idea to manufacture — or start with a free 15-min call if you just want a frank first opinion.
Industrial design is complete but engineering is unresolved
Structural validation, DFM review, and manufacturing feasibility before development investment.
Approaching tooling and need a final engineering review
Pre-production audit before committing to tooling spend — when the cost of a redesign is highest.
The product feels over-engineered or too expensive to manufacture
Component consolidation, geometry simplification, and material review to reduce cost without compromising performance.
A prototype failed and root cause is unclear
Structural analysis and failure mode investigation to understand why and what to change before rebuilding.
Need structural validation before production or compliance testing
FEA and load case development to validate performance against applicable standards before committing to volume.

Not sure where to start?

Idea & Feasibility Review

A fixed-fee engineering consultation for founders and product businesses exploring new hardware. 60-minute session with written summary — fixed fee, contact us for details.

What's technically feasible
Likely manufacturing approach
Major risks and unknowns
Indicative development path and costs
View pricing →

Individual services

Know exactly what you need?

If you already know the service you need, we quote and deliver it as a standalone piece of work.

Why we catch problems others miss

Most engineers see one stage.
We've worked across all of them.

That perspective changes what gets caught before production.

Mechanic
How products fail in the field
Hands-on experience with what breaks, what wears, and what the design missed — before engineering decisions are made, not after.
Designer
How products are engineered
16+ years of structural analysis, design decisions, and the discipline to validate rather than assume.
Manufacturer
How products are actually made
What a supplier can realistically produce, at what cost, and what needs to change before tooling is committed.
Customer
How products are really used
How hardware is actually loaded, abused, and experienced — not how it performs in simulation.

Failure analysis & independent review

When something has already gone wrong

Independent root cause investigation for field failures, warranty disputes, or insurance and legal matters — structural analysis, root cause findings, and a written engineering opinion — independent, with no stake in the original design.

Discuss a failure investigation →

Confidential. Independent technical opinion supported by engineering analysis and written documentation.

Hardware delivered

Some of the hardware
we've developed

All projects →

A selection of projects we can share — much of our work is covered by NDA.

Light EV · Full development
Zoomo One Electric Delivery Vehicle
Award-winning B2B electric delivery vehicle developed from concept through production. Frame optimised through iterative FEA prior to physical build.
Vehicle designStructural analysisManufactureGood Design Award ↗
Consumer hardware · Concept to prototype
Drawbar Bicycle Rack
Adjustable bicycle storage rack for caravan drawbars — designed to accommodate multiple wheel sizes. Full concept ideation, detailed design, and manufacture pack delivered. Prototyped and field-tested.
Concept designCADManufacture packPrototype

Client feedback

What clients say

Read Google reviews →

"I want to keep him all to myself. He's been an exceptional partner — understands the domain and communicates it in a way I can follow, which has been instrumental in moving the design forward. Reluctantly, I highly recommend."

Franc G, FG Designs
Dining Table FEA
GGoogle review

"Carchrie Engineering was recommended to me by a business colleague. I had a clear idea of what I needed but James added a lot of value with his collaborative ideas. He was open to meeting my tight deadline, plus he found me someone to build the product. Six stars."

Matthew D, Hydric Desalination
Custom Mould Design
GGoogle review

"Excellent work in creating the designs for our project. Very helpful in providing all the drawings required to produce the wooden panels."

Andrew G, IceTronics
Custom Enclosure Design

"As usual, delivered on time to the high quality needed. Working with James is always easy and stress free. Responds in a timely manner, is professional, helpful, and his services will continue to be used as and when needed."

Peter B, Private Client
Cam Handle Design

"Fantastic work — prompt, very easy to work with and produced exceptional results. I would and will absolutely recommend his expertise to anyone who needs it."

Anthony R, Touring Essentials
Caravan Product Development

"Very happy with the feedback which helped us make a decision on imported parts. Able to operate under a somewhat vague set of parameters and get the job done. Would hire again."

Ben U, Align Manufacturing
Weld Strength Analysis

Companies & clients we've worked with

Many clients prefer to remain anonymous — further references available on request.

Engineering decisions validated
for production and real-world use

Design review is where we add the most value. Contact us to discuss your project.

Contact us View review packages