Mechanical engineering for teams building real hardware

Laminar Engineering helps startups, small companies, and independent inventors turn rough ideas into reliable, manufacturable products

Laminar Engineering helps startups, small companies, and independent inventors turn rough ideas into reliable, manufacturable products

Ideation
CAD
DFM
Prototyping
Testing
Documentation

Whether you're building something new or improving what you have, I keep the work practical and moving toward something real.

Whether you're building something new or improving what you have, I keep the work practical and moving toward something real.

Why Hire Externally?
Speed · Autonomy · Experience · Execution

An outside engineer is the right fit when you need bandwidth fast, without the overhead of a full-time hire. I step in quickly, work independently, and move the project forward without adding to your management load.

Why Hire Externally?
Speed · Autonomy · Experience · Execution

An outside engineer is the right fit when you need bandwidth fast, without the overhead of a full-time hire. I step in quickly, work independently, and move the project forward without adding to your management load.

About

The Laminar Engineering Design Lab
The Laminar Engineering Design Lab
The Laminar Engineering Design Lab

AJ Dayvie

AJ Dayvie

Product Design, Engineering, and Innovation

Mechanical engineer with formal training (BS ME) and more than a decade taking ideas from sketch to production. My background spans consumer electronics, test fixtures, and simple but innovative products.

In my own shop, 3D printing, machining, and casting let me de-risk concepts with early testing and build functional prototypes in aluminum, steel, brass, composites, plastics, rubbers, and more.

That hands-on loop (design, build, test, repeat) helps 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 and deliver.

Mechanical engineer with formal training (BS ME) and more than a decade taking ideas from sketch to production. My background spans consumer electronics, test fixtures, and simple but innovative products.

In my own shop, 3D printing, machining, and casting let me de-risk concepts with early testing and build functional prototypes in aluminum, steel, brass, composites, plastics, rubbers, and more.

That hands-on loop (design, build, test, repeat) helps 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 and deliver.

Outside of Work

Outside of Work

Montana is a great place to explore, and I spend a lot of my time in the mountains near home — on foot, on skis, by bike, or paraglider. Getting out into the natural world feeds back into how I think and what I want to build.

Montana is a great place to explore, and I spend a lot of my time in the mountains near home — on foot, on skis, by bike, or paraglider. Getting out into the natural world feeds back into how I think and what I want to build.

Montana Mountains
Montana Mountains

Services

The Design Process

I support 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, test-driven refinements, and optimizing designs for mass manufacture.

I support 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, test-driven refinements, and optimizing designs for mass manufacture.

Concept Sketching

Concept Development

Concepts allow exploration of multiple design paths before narrowing in, so the solution space is broad before we commit to a direction. Even with a clear vision, the work benefits from deliberate iteration and reframing the problem. 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 is where I explore function, form, fit, and performance. Iteration is expected — new insights often lead to design pivots and refinement.

CAD Modeling

I choose tools to fit the project, working across Creo, Onshape, SolidWorks, Fusion 360, Rhino 3D, Grasshopper, and a handful of others. 2D tools like Sketchbook, Concepts, and Inkscape are also useful for ideation. I am happy to adapt to your needs. My models stay structured, traceable, and built to handle change. They communicate design intent clearly to fabrication teams.

Research & Development

Not every solution comes from intuition — many surface through investigation, experimentation, and deep domain research. The best ones often come from using known components, materials, or processes in new ways. I keep R&D grounded in practical constraints and real-world performance rather than theoretical perfection.

Optimization

I use FEA, topology optimization, and computational design to go beyond intuition — cutting material, improving thermal and structural performance, and shortening design-test cycles. These tools let me reach geometries traditional methods would overlook.

Design for Manufacturing

Scalable production takes more than a working prototype. Each part has to be manufacturable within its process — injection molding, machining, casting, additive or other — so I align design choices with material properties, aesthetics, and production economics for a smooth transition from development to mass production.

Documentation

I keep documentation clear and revision-controlled so the shop floor has what it needs. 3D models communicate geometry, but well-organized 2D drawings and version control provide the clarity and traceability that reduce errors, support QA, and make the next iteration easier.

Concept Development

Concepts allow exploration of multiple design paths before narrowing in, so the solution space is broad before we commit to a direction. Even with a clear vision, the work benefits from deliberate iteration and reframing the problem. 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 is where I explore function, form, fit, and performance. Iteration is expected — new insights often lead to design pivots and refinement.

CAD Modeling

I choose tools to fit the project, working across Creo, Onshape, SolidWorks, Fusion 360, Rhino 3D, Grasshopper, and a handful of others. 2D tools like Sketchbook, Concepts, and Inkscape are also useful for ideation. I am happy to adapt to your needs. My models stay structured, traceable, and built to handle change. They communicate design intent clearly to fabrication teams.

Research & Development

Not every solution comes from intuition — many surface through investigation, experimentation, and deep domain research. The best ones often come from using known components, materials, or processes in new ways. I keep R&D grounded in practical constraints and real-world performance rather than theoretical perfection.

Optimization

I use FEA, topology optimization, and computational design to go beyond intuition — cutting material, improving thermal and structural performance, and shortening design-test cycles. These tools let me reach geometries traditional methods would overlook.

Design for Manufacturing

Scalable production takes more than a working prototype. Each part has to be manufacturable within its process — injection molding, machining, casting, additive or other — so I align design choices with material properties, aesthetics, and production economics for a smooth transition from development to mass production.

Documentation

I keep documentation clear and revision-controlled so the shop floor has what it needs. 3D models communicate geometry, but well-organized 2D drawings and version control provide the clarity and traceability that reduce errors, support QA, and make the next iteration easier.

Portfolio

A Few Completed Projects

Click to expand each design

CritterBlok Solar Panel Mount

CritterBlok

Solar Hardware

Client: CritterBlok
Role: Principal Engineer
By: Laminar Engineering

A hardware system that secures a protective mesh barrier around solar arrays, keeping out the rodents, birds, and nesting animals that drive fire risk, equipment failure, and costly maintenance. I designed it around installer usability — a streamlined attachment that installs significantly faster than competing systems, engineered for strength, corrosion resistance, and long-term outdoor performance.

Scope:

  • Design for manufacture and assembly

  • Material selection for outdoor durability and cost

  • Prototyping, iteration, and field testing with installer feedback

CritterBlok Solar Panel Mount

CritterBlok

Solar Hardware

Client: CritterBlok
Role: Principal Engineer
By: Laminar Engineering

A hardware system that secures a protective mesh barrier around solar arrays, keeping out the rodents, birds, and nesting animals that drive fire risk, equipment failure, and costly maintenance. I designed it around installer usability — a streamlined attachment that installs significantly faster than competing systems, engineered for strength, corrosion resistance, and long-term outdoor performance.

Scope:

  • Design for manufacture and assembly

  • Material selection for outdoor durability and cost

  • Prototyping, iteration, and field testing with installer feedback

CritterBlok Solar Panel Mount

CritterBlok

Solar Hardware

Client: CritterBlok
Role: Principal Engineer
By: Laminar Engineering

A hardware system that secures a protective mesh barrier around solar arrays, keeping out the rodents, birds, and nesting animals that drive fire risk, equipment failure, and costly maintenance. I designed it around installer usability — a streamlined attachment that installs significantly faster than competing systems, engineered for strength, corrosion resistance, and long-term outdoor performance.

Scope:

  • Design for manufacture and assembly

  • Material selection for outdoor durability and cost

  • Prototyping, iteration, and field testing with installer feedback

Forme Studio Lift

Forme Studio

Home Gym

Client: Interactive Strength
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

End-to-end development of a cutting-edge electro-mechanical exercise machine. On a small team, I designed hundreds of components across years of iteration — from system architecture to motor-driven mechanisms, sensors, and structure.

Scope:

  • System architecture, designed from the ground up

  • Complex assemblies: motor-driven mechanisms, sensors, and structure

  • Parts optimized for sheet metal, CNC, injection molding, forging, and additive

  • Custom cycle-test platform validating 1M+ cycles under load

  • Close work with electronics, software, industrial design, and overseas manufacturing

Forme Studio Lift

Forme Studio

Home Gym

Client: Interactive Strength
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

End-to-end development of a cutting-edge electro-mechanical exercise machine. On a small team, I designed hundreds of components across years of iteration — from system architecture to motor-driven mechanisms, sensors, and structure.

Scope:

  • System architecture, designed from the ground up

  • Complex assemblies: motor-driven mechanisms, sensors, and structure

  • Parts optimized for sheet metal, CNC, injection molding, forging, and additive

  • Custom cycle-test platform validating 1M+ cycles under load

  • Close work with electronics, software, industrial design, and overseas manufacturing

Forme Studio Lift

Forme Studio

Home Gym

Client: Interactive Strength
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

End-to-end development of a cutting-edge electro-mechanical exercise machine. On a small team, I designed hundreds of components across years of iteration — from system architecture to motor-driven mechanisms, sensors, and structure.

Scope:

  • System architecture, designed from the ground up

  • Complex assemblies: motor-driven mechanisms, sensors, and structure

  • Parts optimized for sheet metal, CNC, injection molding, forging, and additive

  • Custom cycle-test platform validating 1M+ cycles under load

  • Close work with electronics, software, industrial design, and overseas manufacturing

Unagi Electric Scooter

UNAGI

Electric Scooter

Client: Unagi
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A lightweight electric scooter with tightly integrated high-performance components. I focused on structural optimization, electronics packaging, and advanced lighting integration.

Scope:

  • Battery, controller, and LED systems packaged into compact structural assemblies

  • Raytrace-based optical optimization for LED placement and light guides

  • High-stiffness injection-molded parts in carbon-fiber-filled PC

  • Composite structures for weight and aesthetics

  • Collaboration with industrial designers and global manufacturing partners

Unagi Electric Scooter

UNAGI

Electric Scooter

Client: Unagi
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A lightweight electric scooter with tightly integrated high-performance components. I focused on structural optimization, electronics packaging, and advanced lighting integration.

Scope:

  • Battery, controller, and LED systems packaged into compact structural assemblies

  • Raytrace-based optical optimization for LED placement and light guides

  • High-stiffness injection-molded parts in carbon-fiber-filled PC

  • Composite structures for weight and aesthetics

  • Collaboration with industrial designers and global manufacturing partners

Unagi Electric Scooter

UNAGI

Electric Scooter

Client: Unagi
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A lightweight electric scooter with tightly integrated high-performance components. I focused on structural optimization, electronics packaging, and advanced lighting integration.

Scope:

  • Battery, controller, and LED systems packaged into compact structural assemblies

  • Raytrace-based optical optimization for LED placement and light guides

  • High-stiffness injection-molded parts in carbon-fiber-filled PC

  • Composite structures for weight and aesthetics

  • Collaboration with industrial designers and global manufacturing partners

Clean Bottle Square (Rendering)

Clean Bottle Square

Water Bottle Innovation

Client: Clean Bottle
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A reusable water bottle with a bold, geometric profile and user-friendly features. I led mechanical development with a focus on material selection and user interaction.

Scope:

  • BPA-free Tritan™ selected and validated for durability, safety, and optical clarity

  • Tactile, easy-to-use latches securing the top and bottom caps

  • Manufacturability and assembly reliability for high-volume production

  • Iterative prototyping aligned to the client's product vision

Clean Bottle Square (Rendering)

Clean Bottle Square

Water Bottle Innovation

Client: Clean Bottle
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A reusable water bottle with a bold, geometric profile and user-friendly features. I led mechanical development with a focus on material selection and user interaction.

Scope:

  • BPA-free Tritan™ selected and validated for durability, safety, and optical clarity

  • Tactile, easy-to-use latches securing the top and bottom caps

  • Manufacturability and assembly reliability for high-volume production

  • Iterative prototyping aligned to the client's product vision

Clean Bottle Square (Rendering)

Clean Bottle Square

Water Bottle Innovation

Client: Clean Bottle
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A reusable water bottle with a bold, geometric profile and user-friendly features. I led mechanical development with a focus on material selection and user interaction.

Scope:

  • BPA-free Tritan™ selected and validated for durability, safety, and optical clarity

  • Tactile, easy-to-use latches securing the top and bottom caps

  • Manufacturability and assembly reliability for high-volume production

  • Iterative prototyping aligned to the client's product vision

Titan Straps

Titan Straps

Utility Straps

Client: Titan Straps
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

Rugged, weather-resistant tie-down straps built for heavy-duty industrial, commercial, and outdoor use. I contributed to ongoing product-line development, with a focus on material selection, functional design, and innovation.

Scope:

  • Design of new products and product variants

  • Co-inventor on patent US12121112B1

  • Prototyping, testing, and design iteration against real-world performance demands

Titan Straps

Titan Straps

Utility Straps

Client: Titan Straps
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

Rugged, weather-resistant tie-down straps built for heavy-duty industrial, commercial, and outdoor use. I contributed to ongoing product-line development, with a focus on material selection, functional design, and innovation.

Scope:

  • Design of new products and product variants

  • Co-inventor on patent US12121112B1

  • Prototyping, testing, and design iteration against real-world performance demands

Titan Straps

Titan Straps

Utility Straps

Client: Titan Straps
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

Rugged, weather-resistant tie-down straps built for heavy-duty industrial, commercial, and outdoor use. I contributed to ongoing product-line development, with a focus on material selection, functional design, and innovation.

Scope:

  • Design of new products and product variants

  • Co-inventor on patent US12121112B1

  • Prototyping, testing, and design iteration against real-world performance demands

Titan Straps

Anova Nano

Sous Vide

Client: Anova
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A compact sous vide cooker designed from the ground up off the original Anova platform. The challenge: fit a motor-circulated water bath, dense electronics, and the resulting heat into a small IP67 enclosure isolated from the water. I worked across electrical, industrial design, and manufacturing to meet every requirement and bring it to market.

Scope:

  • Compact packaging under tight space and thermal constraints

  • IP67 enclosure

  • Water-isolated circulation motor

  • Cross-functional development with EE, ID, and manufacturing

Titan Straps

Anova Nano

Sous Vide

Client: Anova
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A compact sous vide cooker designed from the ground up off the original Anova platform. The challenge: fit a motor-circulated water bath, dense electronics, and the resulting heat into a small IP67 enclosure isolated from the water. I worked across electrical, industrial design, and manufacturing to meet every requirement and bring it to market.

Scope:

  • Compact packaging under tight space and thermal constraints

  • IP67 enclosure

  • Water-isolated circulation motor

  • Cross-functional development with EE, ID, and manufacturing

Titan Straps

Anova Nano

Sous Vide

Client: Anova
Role: Mechanical Design Engineer
At: Pinion Engineering (prior)

A compact sous vide cooker designed from the ground up off the original Anova platform. The challenge: fit a motor-circulated water bath, dense electronics, and the resulting heat into a small IP67 enclosure isolated from the water. I worked across electrical, industrial design, and manufacturing to meet every requirement and bring it to market.

Scope:

  • Compact packaging under tight space and thermal constraints

  • IP67 enclosure

  • Water-isolated circulation motor

  • Cross-functional development with EE, ID, and manufacturing

More Examples

Some additional projects and capabilities

Some additional projects and capabilities

Contact

Start a Converstion

Have a project in mind or a question about my services? Send a message or email and l will get back to you shortly.

Whether you’re exploring an idea or ready to move forward, I'm here to help.

Email

aj@laminareng.com

Located in Bozman, Montana

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