Mechanical and fabrication design is the process of turning an idea, requirement, or problem into something that can actually be manufactured and used. This may involve designing machined components, fabricated structures, mechanical assemblies, custom tooling, or complete systems.

At Rescan 3D, our design process is heavily focused on real-world manufacturing considerations, ensuring designs are practical, cost-effective, and straightforward to build.

We have design experience across a very wide range of applications and manufacturing methods. Some of our recent projects include:

• a large-capacity mobile grain storage trailer design;

• the chassis, bodywork and fuel tank for custom racing buggy to Motorsport Australia regulations;

• numerous industrial skids and lifting frames;

• a bespoke CNC plasma cutting machine design;

• boat canopies and other components;

• engine components such as intake manifolds and accessory mounts/pulleys,

• motor/gearbox adaptor parts for engine conversions;

• custom tooling for sheet metal manufacturing;

• a bespoke pipe-drilling tool;

  and a wide range of other industrial, automotive, marine, and manufacturing projects. 

Our design workflow is heavily focused on designing around existing equipment and structures  - we use 3D scanning extensively to ensure fitment with existing conditions.

Design is the process of solving a problem in 3D; drafting is the process of communicating the solution. To read more about drafting, see our Drafting page [here].

We certainly can. When approached with a clean-slate design request, the first step is to clearly establish the intended function of the part or assembly, as well as performance requirements and success criteria, the required deliverables, timeline, and budget.

Our process for bespoke designs is typically as below:

1. Scope definition

2. Concept design

3. Client review

4. Detailed design

5. Engineering review (if required)

6. Drafting and deliverables

Intellectual property arrangements vary depending on the project. In most cases, clients receive all files and a broad licence to use the design for its intended purpose. Full IP transfer can also be arranged where required.

Usually, yes. Existing equipment can often be scanned, modelled, and modified to improve performance, reduce manufacturing costs, accommodate new requirements, or solve recurring issues. For more information, see our page on Reverse Engineering [here].

Absolutely - that’s one of our main workflows. We use high-accuracy 3D scanning to capture existing equipment or structures - the benefit of this is that we can very clearly see the site conditions, much more accurately and completely than with photos and a tape measure. We can easily match existing mounting locations, and ensure adequate clearance to existing structures.

Often, yes. Even if you don't know exactly what you need, you'll usually know what you're trying to achieve. We can help define the project requirements, explore possible solutions, and develop a design that solves the underlying problem.

Certainly can - a sketch is often a great starting point for a design project. We're also able to combine features from multiple existing designs if your project is more of an "I want this, but different" scenario.

Always - that’s one of the main features of our design process. Our extensive experience in manufacturing means we know all the design tricks that result in higher quality parts, and make parts faster and cheaper to make. We can tailor designs to suit specific manufacturing processes, equipment, or supplier capabilities. We also have a very wide network of manufacturing contacts, so we can help source manufacturers too. Our Drafting page [here] also has lots more information about what goes into our fully detailed manufacturing drawings.

Yes we can. We’ve been working with fabrication companies for nearly a decade, so we’re very familiar with how to design for fabrication and welding processes. Technical considerations like sheet metal K-Factor, bend allowances, weld shrinkage, and assembly sequence are just some of the ways we help ensure fabricated parts are practical to manufacture and assemble.

 Definitely - we’re highly experienced in designing for machining. We have extensive knowledge of machining processes, machine capabilities, tooling, and workholding methods, which we use to design high-quality machined components. Designing parts that can be machined is only half the job though, and we provide full drafting services to properly communicate the technical details of our machined designs. See the Drafting page [here] for more information on what goes into our machining drawings.

Yep, our 3D scanning process makes designing frames to suit specific equipment fast and easy. We've designed numerous lifting frames and structures that have subsequently been certified to AS4991 by independent engineers. Where certification is required, we can coordinate the engineering review and certification process through our engineering partners. 

We certainly can - as with lifting frames, our design process for skids and transport frames relies heavily on 3D scanning to ensure proper fitment of the equipment. We have experience designing structures in accordance with AS1657 requirements for platforms, walkways, stairways, and ladders, and work closely with structural engineers where certification or engineering review is required. 

We do not conduct engineering assessments or certifications ourselves. Where engineering calculations, FEA, or certification are required, we work closely with third-party engineering consultants to provide those services.

We certainly can - we have wide-ranging experience in mechanical design, particularly machine component design. We take special care to analyse limits & fits, assembly tolerance stacks, surface finish requirements, and material interactions. We have access to specs and 3D models for a wide range of bearings, seals, gears/racks, fasteners, lead screws, and all sorts of other power transmission and mechatronic components.

Depending on the project, deliverables may include concept renders, CAD models, manufacturing drawings, STEP files, DXF cutting files, bills of materials, assembly information, and engineering reports from third-party consultants where required.

As much information as you have. This might be a sketch, photos of existing equipment, sample parts, reference drawings, or simply an idea of what you're trying to achieve.

If the project scope isn't fully defined, we can help develop it with you before design work begins.

Design projects can range from a few hours for simple modifications to several months for complex assemblies or new product development. Most projects are completed within one to four weeks. We'll provide an estimated timeframe during quoting and keep you informed throughout the project.

Usually, yes. We work primarily in SolidWorks and can import most common CAD formats including STEP, IGES, Parasolid. The amount of editing possible depends on the quality and format of the source files.