Light EV · Full development Good Design Award
Zoomo One — Electric Delivery Vehicle
Full mechanical design, custom FEA load case, suspension kinematics, and manufacture coordination for a B2B last-mile delivery vehicle.
OutcomeVehicle went to production and won the Good Design Award.
Consumer hardware · Concept to prototype
Drawbar Bicycle Rack
Adjustable caravan drawbar bicycle rack for multiple wheel sizes. Full concept, detailed design, and manufacture pack. Prototyped and field-tested.
OutcomePrototyped and field-tested. Full manufacture documentation delivered for Australian production.
Consumer hardware · Concept to manufacture
Waterproof Silicone Protective Cover
Waterproof silicone cover for Zoomo electric bike electronics. Prototype-tested before tooling, then successfully mass produced.
OutcomeSuccessfully mass produced — prototype validation avoided an estimated $15k–$30k tooling revision.
Automotive · Structural analysis
Trailer Bumper FEA — SAE Class 5
Structural simulation of a vehicle bumper to SAE J684 Class 5 (16,000lb GVWR). Five load cases including failure analysis to determine maximum rated capacity.
OutcomeDesign predicted to pass all SAE Class 5 load conditions. Maximum capacity confirmed at 16,000lb.
Consumer furniture · Structural analysis
Dining Table Frame FEA
FEA and bolt calculations to ISO 19682:2023 for a custom steel table frame before manufacture commitment. Load cases derived through standards review.
OutcomeConnection redesign identified before production — avoiding an estimated $8k–$15k post-tooling revision.
Industrial · Weld defect analysis
Weldment Defect Analysis — AWS D1.1
Analysis of weld defects from a 1,800-piece production batch against AWS D1.1. Lack of fusion, porosity and cracks assessed with qualification recommendations.
OutcomeCritical defects identified and documented. Testing programme defined to qualify the batch before rejection or release.
Manufacturing · Engineering tool
Custom Cut Curtain Rail Calculator
Mathcad tool to optimise cut lengths for custom curtain rail manufacture. Inputs wall lengths and bend angles, outputs exact cut lengths to eliminate manual calculation errors.
OutcomeDeployed for ongoing production use — manual calculations replaced with a validated repeatable tool.
Educational · Product design & documentation
Educational Speaker Enclosure Kit
Laser-cut panel enclosure designed around a Bluetooth speaker electronics kit for educational use. 2D panels optimised for easy cutting and assembly, with detailed step-by-step instructions and an assembly video walkthrough for students building a functioning speaker from scratch.
OutcomeKit designed for easy manufacture and self-assembly, with full documentation enabling students to build a functioning Bluetooth speaker.
More examples available on request — bicycle frame analysis, LEV components, accessible mobility hardware, and industrial jigs. Many projects are under NDA.
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