Mechanical Engineering

Our mechanical engineers transform ideas into robust, manufacturable products.
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Mechanical Engineering and Design for Manufacture

Mechanical engineering at outerspace focuses on precision design, detailed CAD development, and practical engineering for performance, usability, and reliability. We design mechanisms, enclosures, and assemblies that meet technical, ergonomic, aesthetic, and commercial goals.

“I have worked with Outerspace for a number of years on quite a few products, and can highly recommend their services. We even managed to win a Worldstar packaging award on the back of one of their designs.”

John Sprout-Smith

“Our interaction with Outerspace has been truly exceptional. They not only comprehended our requirements but also skilfully transformed our vision into reality. The OSD team played a crucial role in designing and constructing the 1MILLIKELVIN Stress Imaging Camera from the ground up. Their unparalleled expertise and competency truly set them apart! Collaborating with you has been a pleasure, and we eagerly anticipate many more years of successful partnership ahead. – The 1MILLIKELVIN Team”

The 1MILLIKELVIN Team

“Our long association with Outerspace has delivered substantial benefits to our development process. This has resulted in medical products that now receive international attention and are achieving record sales.”

Warwick Freeman – Compumedics

“Outerspace proved to be the ideal partner working closely with our hardware design, manufacturing and software teams around the world to realise our vision”

Geoffrey Wanless

As mechanical engineers, we're broad problem solvers. We bridge the gap between design intent and practical, manufacturable solutions.

We take product concepts and engineer every component to function reliably and be produced efficiently.

We define product architecture, materials, and manufacturing processes early in the design cycle. Using SolidWorks and simulation tools, our team develops detailed CAD, performs tolerance and stress analysis, and creates test plans to validate performance.

We collaborate closely with suppliers, manufacturers, and our clients’ engineering teams to ensure design intent is maintained through prototyping and testing while meeting BOM and COGS targets.

Precision Mechanisms

We design mechanisms that deliver precise, repeatable motion and tactile response, including gear trains, linkages, and actuation systems. Our engineers combine analysis and prototyping to optimise function, durability, assembly, and serviceability.

Sealed and ruggedised enclosures

We create enclosures for challenging environments, including IP-rated, impact-resistant, and thermally managed designs. Our experience spans consumer, industrial, and automotive products, ensuring compliance with ingress, shock, and vibration standards.

High-performance products

We design lightweight, high-performance components and assemblies for scientific, consumer, and industrial applications. Using structural and flow analysis, materials selection, and detailed design, we optimise stiffness, flow, noise, strength, and manufacturability across metal, plastic, and composite components. We conduct thorough IP, strength, and durability testing to validate performance and ensure reliability in demanding environments.

Medical and regulated products

We engineer mechanical systems for medical and laboratory devices, following the principles of regulated product development. We design for usability, precision, and reliability, applying risk management and quality-focused engineering to meet strict performance and documentation requirements.
OUR EXPERTISE

our multi-disciplinary approach to product development underpins years of experience

Systems Engineering and Program Management

Our program and systems engineers manage and coordinate the complex multidisciplinary product development programs and projects we thrive on. They pull together our product development

Industrial Design

Our industrial designers bridge creativity and engineering to design products that are functional, manufacturable and desirable.

Mechanical Engineering

Our mechanical engineers transform ideas into robust, manufacturable products.

Electronic Engineering

Our electronic engineers are focused on the embedded systems of products. This typically starts with requirements and early strategic architecture decisions depending on the goals

Firmware Design

Our firmware engineers breathe life into the electronics hardware we design for products.
Client Projects

the outerspace difference

View work examples of our Mechanical engineering or product engineering projects.

Product Rendering for the Outerspace designed Exercise bike. Designed to have a unique clutch and gamify exercise.

Touch activated spin and touring bike

A developer of interactive fitness equipment with integrated gaming software, needed to develop a new combination spin and exercise bike for the boutique gymnasium and home gym markets.

They wanted to develop a never-seen-before bike that had two distinct modes of operation – spin and exercise bike mode to be housed in one hardware system, operated by a touch screen and supported by their software.

Product photo for the Outerspace designed Thermal Camera for 1MK. Designed to pinpoint stress points before they happen!

Thermal imaging camera

Outerspace’s multidisciplinary team worked with the managing director of LRM Technologies and researchers at DST Group, to design the 1mK thermal camera that quantifies the stresses that cause metal fatigue in aircraft. LRM, a distributor of lasers and thermal imaging cameras, own the licence to apply Defence Science and Technology group software to a thermal camera product idea. LRM’s managing director had a very clear idea about what the DST Group technology could achieve and needed a clear product roadmap to a successful physical product outcome. Outerspace collaborated with LRM and DST Group to clearly identify and plan the product format and pathway needed to create this revolutionary thermal camera.

Product images of the Outerspace designed Micro water filtration system for Watersource. The unit delivers 30 000 Litres of fresh drinking water daily. The image shows the unit installed in regional Australia

Micro water treatment plant

Many communities in remote regions lack reliable access to clean drinking water, relying instead on unsafe or expensive systems. Water Source Australia set out to change this with Brolga, a remote-controlled micro water treatment plant designed to provide safe, continuous drinking water anywhere in the world.

Outerspace partnered with Water Source to take an early-stage prototype and transform it into a manufacturable product. Our role included developing the architecture, electronics, firmware, and mechanical systems, while working closely with Water Source’s software and water treatment experts. Together, we shaped a system capable of producing up to 30,000 litres of safe drinking water a day, suitable for installation in the toughest environments.

our Mechanical Engineering team

meet some of our team members

Ross Perry

Senior Mechanical Design Engineer

Fay Gibson

Senior Mechanical Design Engineer

Brody Payne

Mechanical Design Manager

frequently asked questions

Designs are reviewed for draft, wall thickness, and tooling/tolerance feasibility, with suppliers involved early to confirm process capability. For sheet metal, we validate bend radii, reliefs, and flat pattern accuracy to maintain precision through forming and assembly.
We assess materials based on structural performance, manufacturability, and environmental exposure, aligning with target processes of our preferred suppliers and COGS.
We coordinate architecture and mounting strategies early, defining interface tolerances, EMC shielding, and thermal coupling requirements.

Our experienced engineers work to high standards and adhere strictly to industry standards and compliance regulations. We prototype, test and build excellent hardware solutions for a long product life span.

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