Mechanical & New Product Design, Rapid Prototype Fabrication
Design Innovation Inc. is a Massachusetts-based mechanical engineering and product design practice specializing in new product development, rapid prototyping, and custom device fabrication. Using SolidWorks Pro, CAMworks, CNC milling, 3D printing, and in-house fabrication capabilities, it guides products from initial specification through prototype delivery and early production runs. Its project history spans portable RFID readers, handheld biomedical devices, rugged enclosures, and automotive systems such as the Ford DeWalt Tool Link. It also provides patent agent services, covering patent searching, application drafting, and USPTO prosecution.
Scott LeftonRegistered Patent Agent
Full-cycle mechanical and product design services, collaborating with clients from initial specifications through iterative sketching, mockups, and early prototype delivery.
Integration of complex electronic and mechanical systems, power management configurations, and detailed component specifications.
Design and development of rugged, environmentally sealed enclosures, sheet metal components, and specialized mounting brackets.
Design and fabrication of one-of-a-kind or limited-production devices, assemblies, and manufacturing fixtures.
Development of semi-automated test fixtures incorporating stepper motors, sensors, microcontrollers, and integrated imaging systems.
Fabrication of protective enclosures equipped with safety interlocks, laser-safe windows, and precision slide mechanisms.
Design of custom positioning systems, including vacuum manifolds and precision CNC-milled component plates.
Engineering of specialized passive RFID monitoring tags with anti-tamper, tamper-evident, and self-destruct mechanisms.
Fast and cost-effective physical design iteration and low-to-medium volume production using modern fabrication technologies.
Additive manufacturing utilizing filament-based printers, high-strength resins, clear light guides, and elastic materials.
Precision milling and lathe turning of aluminum, brass, stainless steel, polycarbonate, and carbon fiber materials.
Fast-turnaround laser cutting of custom lids, covers, and structural sheets to support assembly needs.
Alternative tooling methods utilizing 3D-printed polymer patterns and pressure or vacuum forming over stiffened mold cavities.
Technical disclosure support, drawing preparation, and patent prosecution services provided by a registered USPTO patent agent.
Comprehensive searches and analytical feedback to evaluate patentability and reduce potential infringement risks.
Drafting of high-quality patent disclosures and applications with an engineer's perspective on technical details.
Generation of highly precise, USPTO-compliant line drawings sourced from CAD data and photographic models.
Representing clients in patent prosecution proceedings directly before the U.S. Patent and Trademark Office.
Medical Devices · Automotive · Defense · Industrial · Electronics · Aerospace · Robotics
Automotive · Client: Ford Motor Company
Comprehensive mechanical design and engineering support for an in-vehicle tool tracking system. Deliverables included an injection-molded antenna shroud, steel support brackets, a machined heatsink, molded rubber seals, and die-cut thermal pads, alongside modifications to a die-cast environmentally sealed enclosure. The assemblies successfully passed temperature, impact, vibration, and shock testing.
Medical Devices
Design and fabrication of a semi-automated test fixture for a surgical device manufacturer. The system incorporated a feed and tensioning mechanism, a safety interlock cover, custom clamping nests, stepper motors, force and position sensors, and an integrated digital microscope for precise cut evaluations.
Medical Devices
Mechanical design and assembly of a supportive aluminum plate enclosure for manufacturing lasers. The design featured a safety interlock system to automatically shut down the laser when the door opened, integrated laser-safe windows, a precision slide mechanism, a parts holding nest platform, and an air filter.
Defense
Development of a specialized radio handset prototype for demanding communication environments. Designed in close coordination with the electronics team to meet antenna and circuit board spacing requirements, the handset integrated an elastic-resin enclosure, 3D-printed clear light guides, CNC-milled aluminum heatsinks, and a custom flat back-mounted battery pack.