Product Design, Prototype Fabrication, Design for Manufacturing
Our proximity to Silicon Valley leads to several computing and electronics projects every year. Whether it’s a simple 3D printed proof of concept, a cost-effective customization and branding of a pre-made enclosure to create an AI computing solution, or a fully bespoke design tailored to your company’s identity and branding, we can help. On a tight deadline? We can often produce a realistic rendering or physical hardware faster than a larger firm.
We designed a custom enclosure for our client’s motherboard, mating it to a touchscreen and camera. We produced five samples, paired with standard VESA-mount stands, with digitally printed branding.
Eric’s experience with alternative energy started with his involvement in the E85 (ethanol) programs at DaimlerChrysler, continued with hydrogen fuel cell and reformer technology at Nuvera Fuel Cells, and expanded even further as Program Manager for Combined Heat and Power projects at Altex Technologies. Since starting Darby Prototype, he has been hired by various firms to work on alternative-cycle internal combustion engines, hydrogen storage, low emissions burners, thermal management systems for fuel cell trucks, and inverters for electric semi trucks.
These projects have been funded by the Department of Energy, the California Energy Commission, and private equity-funded startups.
Eric was the lead designer and project manager for this system while employed at Altex. This unique co-generation system coupled a micro gas turbine engine, a generator, and a low emissions burner to provide hot water and electrical power for industrial clients.
In-vehicle reformer to convert liquid fuels to hydrogen for fuel cell vehicles. Produced as part of the Nuvera Fuel Cells team
Indirect-fired drier for an agricultural client. Mechanical design and on-site commissioning support by Darby Prototype, fabrication by our client.
Selection of parts designed for the transportation sector. Some were for prototype use only; others represent several design stages and were eventually launched in mass production.
IP-67 Rated Vehicle Control Unit for electric vehicles, designed for mass production die casting.
Prototype high voltage junction box for an electric vehicle. This was designed for CNC machining for SF Motors’ first prototype vehicles.
Where it all began: Eric’s first job after graduate school was at Chrysler Corporation, where he was the Product Engineer for the design and production launch of the first mass-produced C.70 connecting rod in North America. This technology reduces machining cost and increases durability by manufacturing the two piece rod from a single forging. Millions of these parts were produced for Chrysler cars and minivans.
Sometimes, the most unexpected projects are the most rewarding. Here are a few of the more unusual (at least, for a mechanical engineer….) projects we’ve worked on.
Eric provided design, fabrication, and installation assistance on this massive kinetic sculpture by artist Charles Gadeken.
Tap handle for a local restaurant. Machined from fir, CNC engraved, flame-treated, and sealed with polyurethane.
Duplicate of the original built by YouTube star Simone Geirtz; this copy was commissioned by Geirtz for a charity raffle.
We assisted YouTube star Simone Geirtz in building two sets of props for a cereal advertisement campaign in Australia.
Eric designed and fabricated this trophy for the STEM program at his (former) elementary school in St. George, Maine.
