FEA, CFD, CAD, DFMA, Testing: One SDVOSB Engineering Firm That Stays With You
Send your data. Get a free roadmap to the design your program needs.
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The Problem
Most engineering consulting is sold by the hour. When a design fails in test, the vendor bills the redesign, the new prototype, and the retest. Nothing in the deal rewards getting it right the first time. The cheaper the engineering looked, the more the program pays later.
Those costs never show up on the engineering invoice. They show up later in tooling changes, extra prototypes, and warranty claims. And the launch date slips while your team waits for one more loop.
The PPS Approach
Our engineering consulting spends the effort up front to remove your constraint. You get the lowest total-cost design, proven with simulation, CAD, and testing when it is needed. Then a team supports it after it ships. You approve the data at every gate.
Parts cost more than the market will pay. We redesign for material, part count, and process to cut unit cost.
Cut cost on every unit.
How We Solve It
DFMA
Value Eng
FEA
Tooling changes keep landing after release. We lock the geometry with simulation before any steel is cut.
Build the tool once.
How We Solve It
DFMA
FEA
CAD
Every prototype loop costs weeks and budget. We find the failure in simulation, then build to confirm the fix.
Build to confirm only.
How We Solve It
FEA
CFD
Testing
Engineering changes after launch drain your team. We close the design gaps early, before they become changes.
Stop late design changes.
How We Solve It
FEA
CAD
DFMA
Returns and warranty claims hit margin and trust. We model the real loads and fix the design at the root.
Find and fix the cause.
How We Solve It
FEA
Testing
CFD
Design loops push the launch past its window. We plan the path with gates, so decisions happen on time.
Decisions made on time.
How We Solve It
Stage-Gate
FEA
CAD
Your team is at capacity, or a key engineer left. Add a whole engineering team without a hiring delay.
Add a team, not a hire.
How We Solve It
FEA
CFD
CAD
ASME, EPA, or class review stands between you and release. We design to the code and document the work.
Designed to the code.
How We Solve It
ASME
EPA
Class
Facts about how we work, not project results. One team engineers your product from analysis to delivery, and calculations carry a PE stamp where required.
01
A design that removes your constraint at the lowest total cost. You get production-ready CAD and drawings, plus a BOM, supplier package, and test results when your program needs them.
02
FEA and CFD results you review and approve at each gate, before anything moves to prototyping.
03
You own the IP by default, set in your contract.
04
We stand behind the design through production and supply.
We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment.
As an engineering partner for OEMs, PPS runs FEA, CFD, CAD, and DFMA as one loop, with testing when the design needs it. You review and approve the data at every gate. So the design you sign off is the design that ships, backed by the data you approved.
We review your project scope, the data you have, and where you are in development.
You get: free assessment
The path from today to your goal, built with you.
You get: a proposal
Simulation, CAD, and testing in-house, at a lab, or at your site.
You get: data to approve
The design, drawings, and models, checked in our design QC.
You get: the design and the IP
We stand behind the design through production and supply.
You get: a team that stays
Every loop you fund in test is margin lost. Get a free roadmap.
Get Your Free RoadmapOr contract one, or buy the software
Engineering is a team sport
Published Industry Benchmark
40–85%
Fewer parts, published range
Before
Parts added over years of changes, each with its own drawing, supplier, and assembly step.
After
Parts combined or removed, standard processes, and fewer assembly operations.
Boothroyd Dewhurst, Inc., the DFMA software developer, reports this typical range across 38+ published case studies. This is not a PPS result; your roadmap estimates your own savings.
See Our DFMA ServicesFixed scope for one project. A lower-risk place to start when you want to see our work on your data.
Start with one project.
Fits When
One Project
Fixed Scope
From $35K
Scheduled monthly engineering for recurring needs: drawing updates, ASME calcs, or FEA for each sale.
Work on a set schedule.
Fits When
Monthly
Recurring
From $15K/mo
A dedicated PPS team working your program daily, built for long, multi-year development and testing.
Your program, every day.
Fits When
Daily Work
Multi-Year
From $800K/yr
Chosen by the work you have, not a ladder. Some clients start with Diamond.
Mobility & Defense
Single-point design failures ground fleets and trigger costly program reviews.
Find it before flight.
Applications
Flight FEA
Buckling
CFD
Late validation cycles delay vehicle launches across model-year gates.
Ready for the next gate.
Applications
EV Thermal
Crash
NVH
Bucket and structural failures shut down remote mines for days at a time.
Less downtime in the pit.
Applications
Wear
Fatigue
Heavy Haul
Failed classification reviews force long hull redesign and rework loops.
Built for class review.
Applications
Hull FEA
ABS / DNV
Hydro CFD
Process & Compliance
Untested mixing dead zones lead to FDA findings and costly batch rework.
Validate before building.
Applications
Reactor CFD
Mixing
GMP
New sterilizer chambers take long lead times and must fit validated processes.
Engineer the chamber.
Applications
Chambers
ASME VIII
Vacuum
Outdated kiln designs waste fuel and limit the use of alternative fuels.
Cut fuel waste in kilns.
Applications
Kiln CFD
Clinker
Alt Fuel
Energy & Facilities
Promised energy savings disappear when models miss real operating data.
Validate energy savings.
Applications
Turbine CFD
Heat Recovery
Plant FEA
Oversized dust collectors waste capital on compliance equipment you don't need.
Right-size the system.
Applications
Ductwork CFD
NESHAP
Right-Size
Overcooled data halls inflate PUE and waste energy every hour they run.
Cool only what you need.
Applications
PUE
Cooling CFD
Airflow
Do we get a report or a design?
With PPS engineering consulting, you get the design that removes your constraint, not a report about it. Many firms bill for an analysis and hand over a stack of plots. Then your own team must turn the findings into drawings. That gap is where programs stall and where costs grow. Plots alone don't tell a supplier what to make. Drawings still need tolerances that follow ASME Y14.5, and someone has to own them. When that work falls back on your team, the schedule often slips while engineers redo it. Each handoff adds cost, and the reasons behind each change get lost along the way.
We deliver the solution your program needed: production-ready CAD and drawings. Add a BOM, a supplier package, or test results when your program calls for them. The FEA and CFD results are the evidence you approve, not the product. You review the data at each gate. You own the IP by default, set in your contract. If we missed something in our QC, we fix it.
Who owns the design and the models?
From every engineering consulting project, you own the IP by default, set in your contract. Some firms keep the models, or license them back to you. Then every later change sends you back to them. That locks your product to one vendor and hides the evidence behind each decision. When a vendor holds the models, your team can't open the files to check the work, rerun a load case, or brief a supplier. Design reviews slow down. Export rules add more risk. Defense programs must follow the State Department ITAR rules, and loose data handling can stall a program for months, or longer.
At PPS, the IP transfers with the solution, and nothing is held back to tie you to us. You receive the native CAD, the drawings, the simulation files, and the documented results. We sign mutual NDAs before any data is shared. Your files stay in our controlled project folders. Tell us your export-control or customer data rules at the start, and we set up data handling to match.
What happens if a prototype fails in test?
If a prototype fails in test, our engineering consulting team finds out why and fixes the design. Hard engineering carries unknowns. Real loads, material lots, and assembly effects never match a model perfectly. So a test failure is not a surprise to hide. It is data to learn from. Without that view, a failed test turns into a dispute. Nobody knows which assumption was wrong: a load, a material property, or a boundary condition. The vendor bills another loop, and the next prototype repeats the guess. Each blind loop costs weeks, budget, and trust in the model, and your launch date absorbs it.
You approve the data at each gate, so test results are checked against predictions you have already seen. When testing is in scope, we plan the test around the margins that matter most. We correlate the model to the results, following ASME verification and validation practice. If the miss was ours, we fix it. If the test finds a new condition, we scope the change with you.
What support do we get after delivery?
PPS engineering consulting doesn't end with a handoff. We stand behind the design through production and supply, because a design only pays off once it is built, shipped, and supported. Many vendors close the job at delivery and move on. After that, every question becomes a new purchase order. Suppliers change processes, parts go out of stock, and global supply problems stop a line with little or no warning. NIST's Manufacturing Extension Partnership works with U.S. manufacturers on supply chain risk for this reason. When the design team has moved on, your own engineers must then reopen work they never owned or saw.
Our commitments cover our own work. If we agreed to resolve an issue, we fix it. If we missed something in our design QC, we fix it. If your supplier can't make the part, or it can't be bought, within three years of delivery, we fix that too. We guarantee our work, not savings, test results, or dates. The free assessment shows the support your program needs.
Which engagement fits us: Gold, Platinum, or Diamond?
We match every engineering consulting engagement to the work you actually have, not to a fixed ladder you must climb. Hiring for the same work takes time and money. The Bureau of Labor Statistics tracks what one mechanical engineer earns, and that is before software, training, benefits, and turnover. A tier ladder makes you buy more than you need, or wait until you qualify for it. A single hire brings one skill set and a search that can take months. Either way, the work you have today waits, and the constraint keeps costing you on every unit you build and ship.
Gold (from $35K): you have one project and need help with it. Platinum (from $15K/mo): you have recurring work at a steady rhythm. Diamond (from $800K/yr): you have a long development program, often multi-year. Your price comes from the free assessment and roadmap proposal. We price to the value we deliver, not the hours we log. If the value isn't there for you, we'll say so in the assessment.
What does the free assessment include?
The free assessment is the first step of every engineering consulting project with PPS. You send the data set you have, in the format your team already uses. That can be CAD, drawings, loads, test results, costs, or a plain description of the problem. Partial data is fine. A design built on guessed inputs gives a guessed answer. Programs that skip early planning tend to find their gaps late, when changes cost the most. The NASA project life cycle starts with concept studies, well before design and build. So we don't start the engineering until every data set is in.
We review your project scope and work out what it takes to reach your goal. Then you receive a roadmap proposal with scope and approval gates. It could be a full stage-gate program or a short set of FEA models. The assessment is free; on-site visits that need travel are quoted separately. The roadmap, not a stock promise, sets the schedule. NDAs are available; we reply within one business day.
Not sure where to start? Send your data. Get a free roadmap.
Send your CAD, data, and goals. We review your project scope in a free engineering consulting assessment and reply within one business day with next steps.
On-site assessments that require travel are quoted separately.
