Mechanical Design Innovation
I am a hands-on innovation specialist dedicated to quickly bringing early-stage concepts to life. I combine a thorough analytical approach with real-world development and testing, ensuring your product is viable, refined, and ready for production.
Services
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Mechanism development innovative and robust designs that meet motion requirements
Design for assembly ensuring simple, fast repeatable production.
Design for manufacturing refine geometry and materials reducing costs and lead times, close collaboration with manufacturing partners
Computer Aided Design (CAD) clear, accurate models to validate geometry
Parametric modelling flexible designs for rapid iteration and configuration.
Sheet metal low cost designs using standard processes
Topology optimisation using simulation techniques to optimise performance with minimum material usage
Drafting clear, functional drawings for manufacture and quality control
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Finite Element Analysis (FEA) structural simulation to predict stresses, deflections, and failure modes.
Heat transfer analysis and optimisation of conduction, convection, and radiation to manage temperature, efficiency, and reliability
Fluid mechanics and Computational Fluid Dynamics (CFD) Flow simulation to understand pressure, velocity, mixing, and losses in ducts, nozzles, and fluid systems
Impeller sizing selection and sizing of impellers to meet flow, pressure, and efficiency target
Electric motor sizing selecting efficient motors for correct torque and speed
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In-house 3D printing rapid, iterative prototypes
Hands-on prototyping build and assemblywith a variety methods
Design of Experiments (DOE) structured testing for clear insights
Test method development repeatable, reliable validation methods
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Risk management identify and mitigate technical risks
Failure Mode and Effects Analysis (FMEA) anticipate failures and reduce impact
Requirements and specifications writing clear, quantifiable technical definitions
Technical leadership guide teams from concept to delivery
Client Work
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Dyson
At Dyson, I was part of the New Concepts team, leading the development of novel haircare technologies using physics-based design and rigorous physical testing. I am named on two patents, with one pending.
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Recycleye
At Recycleye, I help develop innovative optical-based sorting hardware to efficiently and effectively recover valuable materials from waste streams. My inventions have contributed significantly to business development and they have been filed for patents.
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Zelp
At ZELP, I helped develop a methane oxidation chamber for livestock emissions reduction, contributing to system miniaturisation and increasing operating range.
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Samudra
At Samudra Oceans, I supported the redesign of the mechanical internals of a marine monitoring buoy. Working to tight deadlines, I prototyped and produced all components for a ocean test in my workshop.
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Cove
At Cove, I contributed to the development of sustainable packaging solutions for multiple industry-leading clients, creating innovations that have since been filed for patent protection.
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Make Sense
Make Sense is a start up developing a novel solution for navigating the city while blind. I have developed a custom hinge for their phone holder specially designed for the blind.
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Inivos
Inivos prevents infections by designing devices to sterilise medical equipment. I supported them by solving a specific mechanical problem which involved hands on prototyping iteration and preparing parts for injection moulding.
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All client work is currently under NDA.
The nature of all my work is secretive and I can’t share much details about the solutions I have invented for my clients.
If you want to learn more about my work, contact me to set up an introductory call.
THINGS I MADE
Fastener quick reference tables
I made a PDF with the most common size of nuts, screws, washers and tap drill sizes. I reference it almost everyday.
Download yours for £9.
About
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I am a Chartered Mechanical Engineer with a decade of experience dedicated to innovative hardware and technology development.
My career foundation was built over six years at Dyson in New Product Innovation, where I specialised in rapidly bringing complex product concepts to fruition. I led and supported projects from the initial idea phase through to fully integrated, functional prototypes.
Now, working as a freelance mechanical design specialist, I collaborate on a range of exciting, sustainability-focused projects. I leverage that experience to accelerate early-stage ideas, combining a hands-on development approach with rigorous systems-thinking to deliver viable, proven technology.
Rory Fisher -
Unit 21 Basepoint Weymouth, Jubilee Close Weymouth DT47BS
Dorset+44 7769 585 014