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Services Product Design
Hill Engineering specializes in product development for original equipment
manufacturers that need to supplement their in-house staff. We are skilled
in integrating our extensive knowledge of mechanics, materials and
manufacturing processes to produce effective designs that can be produced
economically. The firm performs all aspects of the mechanical engineering
design of new products. From assistance with the product design
specification through the synthesis of creative solutions, layout,
detailed design and engineering analysis, Hill Engineering will provide
fast, accurate service.
We like to solve difficult problems. Come to us if your staff is
struggling with a problem that is consuming too much time or does not look
solvable. We will take a fresh look at your problem whether it relates to
the product itself or the manufacturing of the product. We have a proven
record of determining the root cause of problems and designing new
approaches to avoid the problems.
We are often called upon to invent while designing. Any invention made on
your job is routinely assigned to you. We can assist in the process of
obtaining patent protection if you desire.
We can improve existing product designs that are not meeting expectations.
Often we are asked to improve designs so that they can be produced more
economically. For instance, we are adept at estimating production cost of
a new product design manufactured in your plant even before detail design
is complete. We also improve designs so they conform to the requirements
of a particular manufacturing process.
We don’t design parts in a vacuum. We can help you locate and qualify
vendors to make the parts we design. 
We use the latest version of SolidWorks to model and document designs. We
pride ourselves on the complete and accurate documentation packages we
produce to accompany your new product design.
Besides designing your new product, we are equipped to fabricate, assemble
and test prototypes rapidly in our in-house prototype shop and laboratory.
We also maintain an extensive network of local vendors that are ready to
supply prototyping services we don’t have in house (sheet metal, plating,
etc.).
If you need help with aspects of building the new product we designed, we
have that covered too. We can design tooling, jigs and fixtures (and build
them if necessary) used for special in-house manufacturing processes (such
as adhesive bonding, welding or machining). We also design jigs and
fixtures for assembly and inspection operations.
We coordinate with your electrical and software engineers to define
product specifications and areas where mechanical design will interface
with their design activity (front panel controls, connectors, power
requirements, etc.).
We often find ourselves in the role of guiding or mentoring your in-house
engineering staff. We welcome the opportunity to share our experience with
your staff in all types of forums.
At Hill Engineering we generally work on a fixed price basis as opposed to
open-ended time and materials contracts. We break a job down into phases.
At the beginning of each phase we will all know exactly what is expected
as an end result, how long it will take to complete and how much it will
cost.
Product Design -- Areas of Expertise
Summarized below are some specific areas in which we have significant
experience. Contact us at cs@hillengineering.com to find out more about
our qualifications for your project!
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Design for high volume production processes such as injection molding, die
casting and stamping.
Design of functional prototypes for rapid confirmation of operation to
specification.
Interface with industrial designers regarding external appearance and
ergonomics of new products. -
Design of sheet metal components and enclosures.
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Pneumatic and hydraulic system design, design of custom rotary and spool
valves.
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Gas separation devices, nitrogen and oxygen concentrators, especially
pressure swing adsorption (PSA). Sorption compressors and vacuum pumps.
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Design for adhesive bonding including hermetically sealed structures such
as pressure vessels and riv-bonding, the combination of rivets and
adhesive in a joint.
Design, analysis and testing of fans, blowers, compressors, pumps and
turbines. -
Design of flexures and compliant mechanisms that completely eliminate all
rubbing contact between parts and the possibility of fretting corrosion.
Included are living hinges in plastic and flexural pivots.
Design for fatigue resistance in low or high cycle applications to
specific probability values
Mechanism design, from detailed kinematics to dynamics. Example devices
include scotch yokes, four bar linkages and over-center toggle linkages.
Seals, both static and dynamic. Experts at applying O-rings in all types
of static and dynamic seals. Pressure balanced face seals as well.
Welded joint design and process/material specification.
Design of unfired pressure vessels for internal or external pressure.
Oceanographic instrumentation, buckling analysis.
Refrigeration system design from normal to cryogenic temperatures,
including vapor compression systems, Stirling and pulse tube machines and
thermoelectrics.
Here are some things Hill Engineering can’t help you with:
Provide bodies to fill chairs at your location
Project management
Production drafting
Electrical engineering, computer engineering or software production
Civil engineering or structural engineering (of buildings), design of HVAC
or other building engineering
Expert witnesses in litigation (we can work behind the scenes on failure
analysis, etc.)
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