Mechanical Engineering

Built to Fit, Built to Last. We transform ideas into robust, manufacturable products.

Built to Fit, Built to Last. We 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.

We packaged a 32kW motor and 18.64kWh battery into a car that's 3.19 metres long, with a folding rear seat and 285 litres of cargo space still intact. That's the VF3. Every millimetre had to earn its place, and nothing about the packaging was accidental.

At OuterSpace, we're broad problem solvers. We take a product concept and engineer every component to function reliably and be produced efficiently, from gear trains and linkages to sealed enclosures rated for shock, vibration and ingress.

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Neither one gets to win on its own.
Design Intent Meets Manufacturing Reality

We define product architecture, materials and manufacturing process early, before the design locks in, because retrofitting manufacturability later costs more than designing for it up front. Using the solidworks suite, and other simulation tools, we develop detailed CAD models, run tolerance and stress analysis, and build test plans that validate performance before a supplier sees the file.

For Medmont's Meridia Vantage, that meant an aluminium chassis built for rapid field servicing, with embedded electronics and precise mechanisms concealed within an ergonomic and on-brand outer housing. The device now holds TGA, FDA and CE certification.

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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.

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In-house capabilities:

CAD and engineering drawing development, tolerance, stress and flow analysis, gear train and linkage design, actuation systems, thermal management, metal, plastic and composite component prototyping, BOM and COGS optimisation

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See it built. Mechanical Engineering Work.

View work examples of our Mechanical engineering or product engineering projects.
AI Occupancy Sensor (Area Pro)
AI Occupancy Sensor (Area Pro)
Flush-mounted, automatically presenting automotive door handle
Flush-mounted, automatically presenting automotive door handle
Autonomous Delivery Vehicle
Autonomous Delivery Vehicle
VF Wild Mid-Size ePickup
VF Wild Mid-Size ePickup
Touch activated spin and touring bike
Touch activated spin and touring bike
Night Mode LED Lighting Kits for LEGO® Sets
Night Mode LED Lighting Kits for LEGO® Sets
Brolga Micro Water Treatment Plant
Brolga Micro Water Treatment Plant
VF3 MINI-eSUV
VF3 MINI-eSUV
Gaming VR glasses
Gaming VR glasses
Ford F-150 LHD to RHD Conversion
Ford F-150 LHD to RHD Conversion
EV docking and charging system
EV docking and charging system
Robust Vehicle Mounted WiFi hotspot
Robust Vehicle Mounted WiFi hotspot
Wearable Personal KinetiGraph
Wearable Personal KinetiGraph
OKTI Mobile EEG
OKTI Mobile EEG
Urban electric bike
Urban electric bike
Negative Pressure Wound Therapy Device
Negative Pressure Wound Therapy Device
Underwater Communications System
Underwater Communications System
Rugged touch panel PC
Rugged touch panel PC
Compact 3D printers
Compact 3D printers
Robotic welding module
Robotic welding module
Agricultural produce analyser
Agricultural produce analyser
 Presto Salon Hairbrush Cleaner
Presto Salon Hairbrush Cleaner
Smart walking stick
Smart walking stick
Animal detection system
Animal detection system
Infant feeding bottle
Infant feeding bottle
Sleep disorder analyser
Sleep disorder analyser
Waterless Urinal Cartridge
Waterless Urinal Cartridge
Marine services pedestal
Marine services pedestal
Sales ordering and EFT POS device
Sales ordering and EFT POS device
Two-way portable radio
Two-way portable radio
Home security system
Home security system
Waterproof and rugged smart device accessories
Waterproof and rugged smart device accessories
Bathroom tapware range
Bathroom tapware range
Flume gate controller
Flume gate controller
Salon trolley
Salon trolley
TourniCare Blood pressure cuff
TourniCare Blood pressure cuff
Drowsiness detection eyewear
Drowsiness detection eyewear
EEG monitor system
EEG monitor system
Cochlear implant testing devices
Cochlear implant testing devices
Tonometer
Tonometer
Smart device case packaging
Smart device case packaging
Waterproof smart device cases
Waterproof smart device cases
Gaming console for dogs
Gaming console for dogs
RFID Wallet
RFID Wallet
RapidFit Jump Rope
RapidFit Jump Rope
4K 360 degree camera
4K 360 degree camera
Lumbar traction device
Lumbar traction device

Process

With over three decades of experience we're experts in product development, accelerating to production and launch.

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01.
Research
We investigate and analyse the business, market and user dimensions of an idea.
02.
Plan
Based on clear user, market and product requirement inputs, we develop system architectures and a project development path.
03.
Design
We generate aesthetic, engineering and technology concepts for initial evaluation.
04.
Engineer
We refine and engineer all of a product’s technical systems including mechanical, electronic and firmware systems.
05.
Verify
We develop test plans and support verification activities against engineering specifications or undertake fault analysis.
06.
Release
We develop full manufacturing documentation and support vendor qualification and selection to facilitate smooth transfer.

Our Expertise

Our proprietary multidisciplinary process balances creative design and advanced technical capabilities across mechanical, electronic, firmware, and systems engineering.
Electronic engineering
01
Electronic engineering
Firmware Design
02
Firmware Design
Systems Engineering
03
Systems Engineering
Industrial Design
04
Industrial Design
Mechanical Engineering
05
Mechanical Engineering

Frequently Asked Questions

01.
How do you ensure manufacturability of complex plastic parts?
Designs are reviewed for draft, wall thickness, and tooling and 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.
02.
How do you select materials for complex assemblies?
We assess materials based on structural performance, manufacturability, and environmental exposure, aligned with the target processes of our preferred suppliers and COGS.
03.
How do you manage mechanical interfaces with electronic or enclosure components?
We coordinate architecture and mounting strategies early, defining interface tolerances, EMC shielding, and thermal coupling requirements.
04.
Can you make my product reliable and successful?
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.

"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

Chief Technology Officer, Compumedics

"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

"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

Chief Technology Officer, Swann Communications

"Our interaction with Outerspace has been truly exceptional. They not only comprehended our requirements but also skilfully transformed our vision into reality. Their unparalleled expertise and competency truly set them apart!"

The 1MILLIKELVIN Team

"...the team at Outerspace Design demonstrate exceptional professional integrity and consistently earn the trust of their collaborators ... I highly recommend Outerspace to anyone who values trust, reliability, and a collaborative approach to professional partnerships."

S Vee

"I had the pleasure of collaborating with the team at Outerspace Design in Melbourne, and I can’t recommend them highly enough. From the outset, their professional and innovative approach to design was evident in every interaction..."

Steve Roche

Ready to discuss your next project. Let's talk.

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