Laminar Engineering

Mechanical engineering for small teams building real hardware.
Laminar Engineering helps startups, small companies, and independent inventors turn rough ideas into reliable, manufacturable products. If you don’t have an in-house mechanical team, I plug in quickly to design, prototype, and de-risk your next product so you can move forward with confidence.

Services

The Design Process

Support across the full product lifecycle: turning concepts into robust CAD, building and refining functional prototypes, and delivering production-ready drawings and documentation. Typical work includes concept development, material and tolerance choices, prototyping, empirically driven refinements, and mass manufacturing optimization.

Concept Development

Early-stage design exploration sets the foundation for a successful product. Multiple design paths are often explored to ensure a broad solution space before narrowing in on a direction. Even with a clear vision, the creative process benefits from deliberate iteration and problem reframing. Typical outputs at this stage include sketches, early mockups, and comparison charts

Prototyping

Prototyping ranges from rough proof-of-concept models to refined 3D-printed assemblies and soft-tooled components. This stage enables exploration of function, form, fit, and performance. Iteration is expected and encouraged as new insights often lead to design pivots and refinement.

CAD Modeling

A strong CAD foundation ensures clarity and precision throughout the product lifecycle. Effective CAD modeling communicates design intent to fabrication teams and enables digital validation. Tools are chosen based on project needs, drawing from a wide skill set that includes: Creo, Onshape, SolidWorks, Fusion 360, Rhino 3D, Grasshopper, Inspire, along with 2D tools like Sketchbook, Concepts, and Inkscape. Modeling systems are structured, traceable, and optimized for change.

Research & Development

Not every solution emerges from intuition—many are uncovered through investigation, experimentation, and deep domain research. Elegant solutions often stem from leveraging known components, materials, or processes in novel ways. R&D work emphasizes practical constraints and real-world performance over theoretical perfection.

Optimization

Advanced simulation tools make it possible to go beyond intuition. Finite Element Analysis (FEA), topology optimization, and computational design are used to reduce material usage, improve thermal or structural performance, and shorten design-test cycles. These techniques enable the creation of geometries that traditional methods would overlook.

Design for Manufacturing

Scalable production requires more than just a working prototype. Each part must be manufacturable within the constraints of its intended process—whether injection molding, machining, casting, or additive manufacturing. Early design choices are aligned with material properties, aesthetic goals, and production economics to ensure a smooth transition from development to mass production.

Documentation

Clear and consistent documentation is critical for successful manufacturing. While 3D CAD models communicate geometry, well-organized 2D drawings and revision control provide the clarity and traceability needed on the shop floor. Robust documentation reduces errors, supports quality assurance, and enables future iterations.

Concept Development

Prototyping

CAD Modeling

Research & Development

Optimization

Design for Manufacturing

Documentation

Concept Development

Prototyping

CAD Modeling

Research & Development

Optimization

Design for Manufacturing

Documentation

About

Hi, I'm AJ

I’m an independent mechanical engineer with formal training (BS ME) and more than a decade of experience taking ideas from sketch to production. I help small teams, startups, and inventors move hardware projects forward quickly, from ideation sketches through prototyping, testing, and design for manufacture.

My background spans complex electro-mechanical devices, test fixtures, and simple but clever one-off products. In my own shop I rely on 3D printing, machining, and casting to de-risk concepts with early testing and build functional prototypes in aluminum, steel, brass, composites, and plastics.

That hands-on loop (design, build, test, repeat) lets you validate ideas faster, make better decisions, and approach production with confidence. Whether you need a focused prototype, a manufacturable design package, or extra mechanical depth I’m set up to plug in quickly and deliver.

Beyond the Office

Montana is a great place to explore. I spend a lot of time out in the mountains near my home. On foot, with skis, by bike, or paraglider. Exploring the natural world feeds back into my creative thinking and drive to innovate.