Engineering Design

Turning engineering concepts into realisable hardware.

Most engineering projects begin with an idea, an inspiration, or an early concept that requires further development
before it can be manufactured.

We help clients transform that starting point into a practical, fully defined design.Requirements are captured early,
concepts are assessed against the constraints that matter, and the selected direction is carried through into detailed CAD, manufacturing information and systems integration.

The aim is not simply to produce a design that works on the screen. It is to create hardware that can be
manufactured, assembled, operated, tested and maintained successfully in the real world.

How We Support Your Project

We can join at the earliest concept stage, provide additional engineering resource to an existing team, or take responsibility for a defined design work package. Where required, the same team can continue with analysis, manufacture, testing and deployment.

Core Services

Requirements capture and concept development workshops
FEED studies
Detailed CAD design for mechanisms, structures and complex assemblies, using Autodesk Inventor supported by hand calculations from first principles
Design for manufacture, assembly, operation, testing and cost
Manufacturing drawings and bills of materials
Systems integration, including electrical controls, sensors, access and maintenance requirements

Who We Work With

Clients with an idea, a rough sketch, or an early concept that needs to become buildable hardware, as well as clients with an existing design that needs to be made manufacture-ready before it can be manufactured.

Typical challenges we solve

A concept that works in principle but hasn't been proven out in detail
A design that looks finished on screen but hasn't been checked against how it will actually be made
Limited in-house engineering capacity to deliver design and drawings on time
Helping clients understand the business case and the need for prototypes and testing

TALK TO AN ENGINEER

Book a Consultation With Our Engineering Design Lead

Tim Warren

Operations Director

Chartered engineer with 25 years' experience of product development in aerospace and offshore renewables. Tim has led numerous projects through the full engineering lifecycle, from concept to build, test and operation.

His experience of aerothermal, mechanical system design, procurement, manufacture and operation means he brings a balanced and thorough perspective to any project. Tim also leads our concepting workshops, Verification and Validation process and cost reduction workshops.

Case Studies

View a selection of case studies where we outline the challenges, approach and outcome.

Offshore Vessel Charging Systems for Charge Offshore

Blackfish worked with MJR Power & Automation to develop a multiple offshore vessel charging systems, including a 250kW prototype and a 1MW commercial demonstrator system. Blackfish design scope included the on turbine cable reeler with hydraulic compensation mechanism, the connector bodies and umbilical integration, and the vessel side catcher assembly with load latch and connector stab mechanism. The Blackfish team also managed procurement, manufacture management, supported the assembly and verification testing, delivering a fully tested system supporting the electrification of vessels around offshore infrastructure.

Challenge

The system needed to transfer high electrical power safely in a demanding marine environment while accommodating engagement, sealing, cooling and vessel movement.

Approach

Blackfish developed the connector layout, engagement method, sealing and cooling arrangements, and redesigned the rotational compensation system. The team also managed procurement, manufacture, assembly and verification testing.

Outcome

The project delivered a fully assembled and tested offshore charging system, supporting the practical electrification of vessels operating around offshore infrastructure.

VIEW CASE STUDY

Mocean Energy Wave Energy Converter

Blackfish has worked with Mocean Energy since 2017, helping design, fabricate, assemble and commission its Blue X wave energy converter, installed in Orkney in 2021. Blackfish was responsible for almost the entire mechanical design and structural assessment, and the partnership continues on further Mocean projects.

Challenge

The project required a complete mechanical and structural solution for a large prototype operating in a demanding marine environment.

Approach

Blackfish designed the main structure, mooring and lifting points, equipment mountings and PTO test rig, completed stability assessments, and supported fabrication, assembly, quality control and wet commissioning.

Outcome

Blue X was successfully commissioned and deployed for testing at the European Marine Energy Centre, establishing an ongoing engineering partnership between Blackfish and Mocean Energy.

VIEW CASE STUDY

Bombora Wave Power - Cell Module

Blackfish was responsible for the main cell module design on Bombora's novel mWave device, in close collaboration with the client. The work covered concept design, attachment mechanisms, auxiliary systems and detailed FEA, alongside development, test rig design and serial manufacture of Bombora's novel air valve system.

Challenge

Bombora required a robust main cell module and a novel air valve system capable of meeting demanding structural, fatigue and operational requirements.

Approach

Blackfish completed concept and detailed structural design, finite element analysis and manufacturing drawings, then developed and tested scale valve prototypes through wind-tunnel, pressure and life-cycle testing.

Outcome

The work supported the design and build of the mWave demonstrator and delivered proven full-scale engineering solutions for critical structural and valve systems.

VIEW CASE STUDY