Complete solutions for electro-mechanical hardware
Level Engineering provides contract engineering and manufacturing services specializing in electro-mechanical hardware. It delivers mechanical design, electronics development, hardware prototyping, and in-house contract manufacturing for machined, formed, welded, and electronic assemblies, ranging from single-unit prototypes to low-to-medium volume production runs.
Christopher D'EliaEngineer, President
Nicholas BachusResearch and Development Program Manager
Trevor MetzEngineer
Nicholas GalloEngineer
Charles RinghamEngineer
Alex HillEngineer
Meghan SylviaEngineer
Integrated engineering solutions for complex multidisciplinary devices and assemblies, spanning initial design modeling through to manufacturing release.
CAD modeling, finite element analysis (FEA), and computational fluid dynamics (CFD) for structural and thermal systems.
Embedded systems engineering, including circuit design, PCB layout, and firmware development.
Optimizing component layouts, tolerance stack-ups, and fabrication methods to ensure scalable and cost-effective production.
In-house precision fabrication and assembly services bridging the gap between initial concepts and volume production runs.
High-precision milling and turning using multi-axis CNC centers, including full 5-axis machining and automated pallet changers.
Precision wire electrical discharge machining utilizing 5-axis capabilities for complex geometries and tight-tolerance components.
Small-batch and prototype printed circuit board assembly featuring in-house pick-and-place lines and reflow soldering.
Specialized custom fabrication, including TIG welding, precision thermocouple junction welding, and sheet metal forming.
Comprehensive measurement, testing, and data acquisition services to characterize hardware performance and validate designs.
Precision strain gauge installation, load cell development, and material characterization including residual stress measurement.
Development of customized vacuum and pressure decay testing fixtures, leak testing, and fluid flow validation systems.
Product testing inside controlled temperature chambers configured with custom sensor arrays to evaluate environmental durability.
Design and integration of custom test fixtures, multi-axis motion control systems, and automated data acquisition setups.
Medical Devices · Consumer Products · Electronics · Research Facilities · Aerospace · Automation & Controls
Consumer Products · 2022 · Client: Benchmark
Conducted a two-dimensional tolerance stack-up analysis using worst-case and statistical sum-of-squares methods to verify the center-plane planarity of the Benchmark 1.1 and Benchmark Pro bike frame welding fixtures. The analysis identified critical washer tolerances and guided assembly shim adjustments to achieve high-precision alignment.
Consumer Products · 2021
Designed and installed a custom pneumatic accumulator tank system to stabilize air pressure during tool changes on a Haas vertical machining center. The setup bypasses regulator response latency by sourcing high-volume surges directly from a dedicated reservoir, ensuring smooth tool changer operation without extending compressor load cycles.
Electronics · 2021 · Client: MicaSense
Developed an optimized manufacturing and finishing workflow for the MicaSense RedEdge camera enclosures. Utilizing a 4-axis Haas CNC mill with custom soft-jaw fixtures, the process integrated a brush-grinding operation within the machining cycle to eliminate cosmetic tool marks prior to anodization and custom laser engraving.
Electronics · 2019
Designed and prototyped a custom printed circuit board assembly (PCBA) for current measurement and interruption. The USB-powered board features optoisolated digital inputs, a Hall effect current sensor, and relay outputs, interfacing directly with an Mbed Nucleo development board for concept validation.