We work with workshops, race teams, manufacturers and individual customers. Bring us an idea, a sample, a drawing or simply the problem the component needs to solve.
Start with what the part needs to do
What does the part do and what does it mount to? What loads, temperatures and fluids will it see? How much space is available, and can it be accessed for service? Those questions shape the design together with the choice of material and process. We plan the mounts, mating surfaces, tool access, machining and assembly early.
Hands-on work with cars, engines and race vehicles, along with CAD/CAM and CNC programming, helps us connect the way the part needs to work with how it will be made and fitted.
3D scanning, reverse engineering and CAD
To reproduce an existing component or develop a new one for a tight space, we start by scanning and measuring the part, assembly or installation area. That gives us the reference geometry for design.
In CAD, we account for mating surfaces, mounting points, adjacent parts and the intended manufacturing process. We can recreate a design from a sample, make changes to it or develop a new part. The same approach works for a single component or a larger assembly, such as fitting hardware around the engine, transmission or chassis.
Material, manufacturing process and prototype
We select materials for the loads, temperature, fluid exposure, weight and surface requirements. We consider manufacturing options and cost at the same time. Depending on the project, we can use CNC metal machining, polymer or metal 3D printing, composites or a combination of processes.
Where useful, we make a prototype to check fit, interfaces and assembly access. We use the findings to revise the design and prepare the next prototype or the production version.
What we can help with
- New parts. Develop the layout, model and material selection through to manufacture.
- Reverse engineering. Recreate the design from a sample and prepare it for production.
- Component redesign. Adapt geometry, mounts, passages or other features for new operating conditions.
- Prototyping. Make samples for fit checks, design verification and testing.
- Tooling and fixtures. Design fixtures and auxiliary components for assembly and production.
- Batch production preparation. Refine the design for the selected process and repeat manufacture.
In-house engineering and specialist manufacturing partners
Oleg Zaytsev leads the engineering work, including scanning, reverse engineering, design, material and process selection, and prototype development. Depending on the project, this also includes CAM preparation and CNC programming.
Our long-term partners provide turning and milling, including five-axis and large-part machining with working envelopes of over one metre. They also offer polymer and metal 3D printing and composite fabrication. We select the process and manufacturing partner to suit the part and coordinate design changes through to production.
A development partner for workshops and companies
If your team needs a custom component for a customer's car, race vehicle or product of its own, we can handle the design and organise manufacturing. You can bring us in for scanning, design or a prototype, or ask us to take the part through the full process. We plan around your team's build schedule and how the part will be used.
Examples from our work
Our work covers engine, intake, lubrication and drivetrain components, as well as housings, mounts and production tooling. These projects show how different requirements shape the design.
McLaren 720S inlet pipes. Airflow analysis, complex internal geometry, CAD/CAM and CNC manufacture, with a published before-and-after dyno comparison.
View project ↗Toyota 2JZ modular dry-sump pan. A low-profile design that accounts for the engine position, steering rack, oil system and manufacturing process.
View project ↗BMW M G-series differential cover. From 3D scanning the existing part through CAD design to a machined metal prototype.
View project ↗What does your part need to do?
Send photos, a sketch, a drawing or a model, plus the expected operating conditions and quantity. If you have a sample, tell us which features you want to keep and what needs to change. We'll identify the information we need, propose an approach and tell you what it takes to estimate cost and timing.