Product Development

From concept to prototype, we turn your ideas into tangible products ready for testing and validation.

At Mech Flow Designs, our Product Development services help transform concepts into market-ready solutions. We provide rapid prototyping and 3D printing for fast iterations, injection moulding for scalable production, and custom fabrication including engraving and woodwork for unique design needs. By combining precision engineering with modern manufacturing methods, we accelerate development cycles and reduce time-to-market while ensuring quality and performance.

  • 3D Printing & Prototyping Test, refine, and validate your designs quickly through rapid prototyping and advanced 3D printing.
  • Injection Moulding Reliable moulding solutions for producing scalable, durable, and cost-efficient components and products.
  • Custom Fabrication Specialized engraving and woodwork services that bring creativity and customization to your product designs.

Our Work in Action

Consumer Electronics

Blackboard Transact Card Machine

A detailed 3D model was created to showcase the design and structure of the Blackboard Transact Modular-1 card machine. The compact housing was modeled with modularity in mind, featuring precise detailing of the card reader and interface components. The design emphasized both functionality and manufacturability, while the clean, professional presentation supported visualization and prototyping needs.

Flat Charging Station

A sleek and functional CAD model was designed to provide a compact charging solution for Apple devices. The minimalist flat-base design included dedicated slots for an iPhone and Apple Watch, emphasizing space efficiency and usability. With its modern aesthetic and clean presentation, the model served as an effective concept for visualization and prototyping.

Wireless Mouse

A precise CAD model was developed to showcase the ergonomic and functional design of a modern wireless mouse. The model featured a contoured shape for comfortable use, detailed button and scroll wheel layouts, and a compact form optimized for usability. Clean and realistic presentation made it suitable for both product visualization and prototyping applications.

Game Controller

A 3D model was developed to represent the ergonomic and functional design of a modern game controller. The design featured comfortable grips, accurate detailing of buttons, triggers, and joysticks, and a user-friendly layout optimized for usability. With its clean and realistic presentation, the model was ideal for product visualization and prototyping applications.

Injection Moldings

Cloth Hanger

A cloth hanger was designed and manufactured using ABS material for strength and durability. The 4-cavity mold design maximized batch productivity, with wall thickness optimized at 2.5 mm for a balance of rigidity and lightweight construction. Conformal cooling channels reduced cycle time to under 22 seconds, while a fan gate system ensured smooth material flow across the 420 mm length. Precision mold inserts maintained ±0.1 mm accuracy in the hook section, enabling each hanger to reliably hold up to 5 kg without deformation.

Flushing Valve

A flushing valve was manufactured using polypropylene (PP, melt flow index ~12 g/10 min) with a 2-cavity injection mold for production efficiency. Draft angles of 2° ensured smooth ejection, while Ø8 mm cooling channels around thicker 3.5 mm wall sections minimized warpage. A submarine gate design enabled automatic de-gating, keeping cycle time near 28 seconds. Precision inserts with ±0.05 mm tolerance were applied to sealing surfaces, ensuring leak-free assembly. The process delivered high dimensional accuracy and consistency for reliable water pressure applications.

Door Handle

A durable door handle was produced using polyamide (PA6 with 30% glass fiber, tensile strength ~170 MPa) through single-cavity injection molding. A side-action tool was designed to accommodate undercuts, with 1.5° draft angles applied to preserve aesthetics during ejection. Cooling channels (Ø10 mm) were positioned near the 5 mm thick grip to prevent shrinkage, while a hot runner system minimized material wastage and ensured superior surface finish. Precision inserts at screw-mount locations (±0.02 mm tolerance) guaranteed secure fastening. The result was a strong, dimensionally stable handle, tested to withstand over 100,000 usage cycles.

Gallery

Medical Electronics

Femoral Impactor

A detailed 3D CAD model of a femoral impactor was developed in SOLIDWORKS, including the impaction head, carrier, arms, and ergonomic handle assembly. Designed to deliver controlled forces for accurate placement of femoral implants in hip and knee surgeries, the device was engineered using biocompatible stainless steels (17-4 PH and 316L) with polished finishes for durability and repeated sterilization. It was tested to withstand axial loads up to 5 kN and more than 100,000 strike cycles without structural failure. The ergonomic handle ensured comfortable ambidextrous use, while the assembly allowed easy disassembly and compatibility with over 500 steam sterilization cycles at 134 °C.

Neurostimulation Headset

A 3D CAD model of a neurostimulation headset was developed in SOLIDWORKS, featuring dual electrode pads integrated into a lightweight, compact design. The adjustable fabric sheath provided a secure yet comfortable fit for varying head sizes, ensuring consistent electrode contact during extended use. Ergonomics and usability were prioritized by minimizing bulk while maintaining stability. Soft, skin-friendly interfaces improved comfort, and material choices included biocompatible polymers and medical-grade fabrics—supporting scalability toward real-world medical applications.

Prosthetic Gripper – ACCBI-1

A prosthetic gripper prototype was designed in SOLIDWORKS to deliver an affordable and accessible upper-limb solution. The gripper featured multi-finger actuation for adaptive grasping of objects with varying shapes and sizes. Lightweight and modular construction combined biocompatible polymers with aluminum components to ensure strength without adding bulk. A simple actuation system—motor-driven or tendon-based—was integrated for ease of maintenance and low production cost. Designed with ergonomic proportions, the gripper mimicked natural hand movements while providing reliable grip force for daily tasks. Accessibility and scalability were prioritized, making it suitable for low-resource settings and mass production.

Hand Prosthesis – ACCBI-2

A fully mechanical bionic hand was designed and modeled in SOLIDWORKS, eliminating tendon strings by employing rigid rod linkages for precise finger actuation. The system integrated miniature N20 gearmotors and an SG-90 servo motor to enable independent thumb and finger motion. A feedback system using variable resistors tracked finger bending angles, providing proportional control for a more natural grip. Powered by four 18650 lithium cells, the prosthesis achieved a balance of compact size, portability, and sufficient runtime for daily activities. The lightweight yet ergonomic frame reduced user fatigue, while the design emphasized cost-effectiveness, adaptability, and scalability—making it suitable for further development into practical prosthetic applications.

Behind every line and model lies our passion to create, refine, and deliver excellence.

  • mechflowdesigns@gmail.com
  • +92 3135166673

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