Warley Design Solutions Ltd.

Experienced product development professionals who provide innovative mechanical design solutions for electronic products in industry sectors where reliability and performance needs to be assured.

Warley Design Solutions Ltd is a company of highly experienced product development professionals who provide innovative mechanical design solutions for electronic products.  We have a background in industry sectors where reliability and performance needs to be assured; such as datacomms, Telecomms, computing & information security.

We can fully support your product development needs.  We can work directly with an electrical hardware team and provide holistic product development services or can provide “à la carte” design services such as perform thermal assessments, generate Cost Reduction business cases or simply to add bandwidth to existing mechanical design resources.

Our ethos was established over many years of working in global product companies where quality and reliability were paramount.  We have additionally worked in Electronics Manufacturing Services (EMS) companies and have benefited from a hard focus on Cost Reduction and design optimisation for manufacture.  Our experiences of working on both sides of the wall over which design is traditionally thrown give us a perspective that we exploit to deliver quality designs that are optimised for cost at a given manufacturing volume.

Our product design services offering includes mechanical architecture, detail mechanical design & documentation, thermal management, product safety, EMC engineering, prototype build-and-test to customer specified & regulatory requirements.  We will provide you with the concurrent engineering experience you require to realise your product and reliably deliver it to your market

We believe we can uniquely bring to you the competencies and quality of output expected from working with large, multi-national companies but with flexibility, agility and the customer-centric focus of a smaller company who is both geographically and culturally closer.

Products and services

Prototype build & test

Using our established connections with prototyping facilities we can utilize rapid and traditional (e.g. metalworking) prototyping techniques to generate prototypes for fit, form and functional testing to validate the concept.

We view prototype build and confidence test as a critical step to ensure that the concept will fully meet all the previously documented fit, form and functional requirements.

The systems we prototype typically feature sheet metal parts, parts machined from solid, cooling systems, cable harnesses, labels, plastic parts produced by rapid prototyping techniques such as Stereo lithography, urethane casting etc. 

For full information on this service please see our web site: http://www.warleydesign.co.uk/prototype-build-and-test.htm

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Thermal Management

We offer a complete thermal management service: from Computational Fluid Dynamics (CFD) simulation, model validation & improvement of existing systems to thermal management architecture, detail design / implementation and verification testing for new designs.

With the drive to package more features into equipment and the need for faster systems with higher throughput capacity / functionality comes an increase in power density. Good thermal management can bring benefits through resulting in safer, quieter, cheaper and more reliable systems.

For full information on this service please see our web site: http://www.warleydesign.co.uk/thermal-management.htm

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Compliance Engineering

Compliance Engineering is the term we give to ensuring that the design will meet the stated customer and regulatory requirements before testing. Failure of regulatory testing would necessitate a costly design re-spin & hardware rebuild that may result in loss of competitive advantage or at worst the market opportunity being missed entirely.

We de-risk customer-specified and regulatory non-compliance through working at the very beginning of the development process to gain an understanding of the requirements and the intended geographic markets, determining the route to compliance and then ensuring that the design evolves in such a way that non-compliance is never a risk.

Confidence testing is carried out on pre-production models as part of our development process and we can manage all test and compliance activities as soon as production-quality hardware is available.

For full information on this service please see our web site: http://www.warleydesign.co.uk/compliance-engineering.htm

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Product Cost Reduction

Having evaluated a benchmark design using best-in-class tools, we redesign and then re-evaluate. We present the benefits in the form of a fully costed business case where a return on investment (ROI) is clearly stated.

Our value proposition is to use our experience in Cost Reduction before the event: in a pro-active way so that the concept delivers the performance required at the optimum cost-point ..... we like to think of it as Cost Avoidance. This enables us to potentially access much greater cost savings by influencing the decision-making earlier in the project.

For full information on this service please see our web site: http://www.warleydesign.co.uk/cost-reduction.htm

Mechanical Design Services

We will bring you the greatest benefit through using our multi-disciplinary design capability at the concept design stage to perform the trade-offs necessary to achieve balance between conflicting requirements (e.g. cost-effective design solutions, design for manufacture & assembly, Time-To-Market and functional performance.

We will bring extensive knowledge in:

  • System Architecture / trade offs
  • Design for Manufacture & Assembly
  • Cost Reduction / Cost Avoidance
  • Thermal Management
  • EMC Containment
  • System Interconnect / Cable Management
  • Fibre-optics Management / Handling

We offer design services using a choice of SolidWorks and the Pro/ENGINEER suite of tools and can provide files in native, STEP, IGES, eDrawing and DFX formats plus viewable .pdfs of all 2D outputs

For full information on this service please see our web site: http://www.warleydesign.co.uk/mechanical-design.htm

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