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For innovative product design and development

Expertise

TechSynergy Limited are specialists in the design and development of mechanical and electro-mechanical products and assemblies.

Simple component design through to the design of complex mechanisms and enclosures is quite standard. Designs make best use of all available manufacturing techniques, processes and materials taking into account the obvious criteria of cost, production quantity, life cycle, product purpose etc.

Product types
TechSynergy have been involved in the design and production of a diverse range of product types. These include:

  • Precision two axis motorised camera platforms for use in long range military surveillance applications
  • Manually steered pan and tilt units with integrated precision electronic angle measurement
  • Tripods and masts
  • Control consoles
  • Electronic enclosures
  • Camera housings
  • Packaging

Design considerations
Designs have considered the following criteria:

  • Production quantities from single prototypes through to series production running to thousands of units
  • Operation at commercial and military temperature ranges i.e. 0 to +70 deg C and -55 to + 80 deg C depending on product application
  • Static and dynamic environmental sealing against dust, sand, ice and immersion
  • EMC
  • Proof against vibration and shock
  • Ergonomics
  • Aesthetics
  • Wear
  • Operational stress
  • Cost

Characteristics
Designs have featured the following:

  • Static and dynamic sealing for both environment and EMC
  • Fluids for damping of motion
  • Springs
  • Optics
  • packaging of electronic assemblies
  • Accommodation of electrical cabling and connectors
  • Chemical and paint finishes
  • Precision bearings
  • Structural elements i.e. beams, levers etc.
  • Specialist lubrication
  • Gear, chain and belt drives
  • Motor drives
  • Encoders
  • Precision backlash free mechanisms
SolidWorks

Manufacturing technologies
Designs have utilised the following technologies:

  • Sand casting, including precision variants
  • Investment casting
  • Pressings and stamping
  • Sheet metal fabrication
  • Photo etching
  • CNC milling and turning
  • Injection moulding
  • Gravity and high pressure die casting
  • Composite lay-up
  • Rapid prototyping processes i.e. laser sintering, stereo lithography etc.
  • Structural bonding and adhesives
  • Welding
  • Laser and water jet cutting

Materials
Designs have utilised the following materials:

  • Wrought and cast aluminium
  • Steels
  • Non ferrous alloys i.e. brasses and bronzes
  • Thermoplastics
  • Thermoset plastics
  • Elastomers
  • Carbon and glass fibre composites
  • Glass
  • MDF
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casting

Machined casting