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BioFlex Engineering

Every job starts as a part you can hold.

Concept design, CAD, and 3D printed prototypes. Before any tooling is committed, we put a physical part in front of the people who will actually use it.

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Two engineers at a workstation reviewing a 3D model on dual monitors, one pointing at the assembly on screen while the other works at the keyboard

From CAD model to the finished part.

The design pack is the deliverable. This is what one looks like when it reaches the print bed, the bench and the workshop.

Prototyped · tested

Fig. 01

3D CAD render of the powder transport bin with its latched lid open and carry handle on top

Model

The full-size prototype printed in blue, latched shut on the workshop bench

Printed

The printed bin on a bench scale reading 2495.5 grams, confirming the carry mass

Weighed

Powder transport bin, printed and tested

A hand-carried, latched container for moving powder safely between process areas. We printed it full size, weighed it to confirm the carry mass at 2.5 kg, and drop-tested it. The test found the hinge fastening as the weak point, and that is the change carried into the next revision. This is the loop on every project: model it, print it, test it, and fix what the test found rather than what the model suggested.

Full-size printed prototype · 2.5 kg carry mass verified · Drop tested · Hinge fastening revised

Design to built

Fig. 02

3D CAD render of the wire winding fixture, showing the spool carrier, guide arm and pinned ring

Model

The winding fixture built in stainless steel, standing on a desk beside the workstation it was designed at

Built

Wire winding fixture, model to bench

A manual winding station with an indexing spool carrier, an adjustable guide arm and interchangeable pins, in stainless steel and engineering polymer on a machined base plate. The model fixed the geometry and the adjustment ranges before anything was cut, and the built unit is that same design with nothing redrawn between the two.

3D CAD · Stainless steel and engineering polymer · Indexing spool carrier · Interchangeable pins

Design to finished tool

Fig. 03

3D CAD model of the custom cutting blade inserts

Design

The manufactured cutting blade held in hand, showing the precision-machined finish and final geometry

Manufactured

Cutting blade inserts, start to finish

A set of custom cutting blade inserts for a thermoform packaging line, taken from CAD model to installed tool. The blades were CNC-machined from hardened tool steel to the dimensional tolerances and surface finish specified at design stage, and fitted directly to the customer's existing tool block without rework. The design pack was the deliverable that made that possible: the workshop quoted and built from it without a single clarification call. Concept to finished tool in weeks.

3D CAD · Hardened tool steel · CNC machined · Direct retrofit · Concept to manufacture in weeks

Services

Concept design and feasibility
Sketches, layout options, and an honest feasibility view before anyone commits.
3D CAD modelling
3D CAD models of parts, assemblies, and full equipment layouts.
3D printed prototypes
A physical part to check in the hand, on the bench, or on the line.
Design-for-manufacture review
The design checked against how it will actually be cut, formed, or moulded.
Tolerance, clearance, and fit checks
Stack-up and motion studies resolved on the model, not on the shop floor.
Reverse engineering from a sample
A worn or obsolete part measured, modelled, and re-drawn for manufacture.
Manufacturing drawings and BOMs
A release pack a workshop can quote from and build to without a phone call.
Short-run printed parts
Bridging parts that keep a line moving while production tooling is made.

How a design gets to a part

The same five operations run on a medical fixture, a thermoform tool, and a biogas dosing rig. What changes is the constraint set, not the sequence.

  1. OP 10

    Brief and constraints

    What the part has to do, where it has to fit, who has to handle it, and what it has to comply with. Written down before anything is drawn.

  2. OP 20

    Concept and layout

    Two or three credible routes sketched and compared against the constraints, so the option that gets modelled is the one that survived a comparison.

  3. OP 30

    CAD model

    The chosen concept modelled in 3D CAD, with clearances, tolerance stack-up, and motion resolved on the model while changing it is still free.

  4. OP 40

    Print and review

    A printed part put in front of the operators and engineers who will live with it. Ergonomics, clearance, and fit are judged by hand rather than argued over a screen.

  5. OP 50

    Release for manufacture

    Drawings, BOM, and material specification issued once the physical review is closed out, so the machined or fabricated version is built from a design that has already been held.

Got an idea that needs drawing?

Send us a sketch, a photo, or a worn part. We'll come back with a scoping outline within 5 business days.

Start a project