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Home › Mechanical Engineering Services › Mining Equipment Engineering Services
For mining machinery OEMs: crushers, conveyors, screens, and haul equipment
Keep your machines working longer. Free assessment and roadmap.
The challenge
Rock impact and overloads bend frames, crack welds, and break buckets out in the field.
Review: Field failures
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What changes
Our mining equipment engineering services model impact and contact in frames, buckets, and booms.
How: Nonlinear FEA →
The challenge
Cyclic loads and vibration grow cracks at welds until a frame or boom fails in service.
Review: Inspection
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What changes
Vibration and fatigue analysis find hot spots, so welds and details are fixed early.
How: Vibration Analysis →
The challenge
Premature wear in mining equipment eats custom wear parts and castings, each with high prices and long lead times.
Review: Cost target
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What changes
DFMA moves parts to standard processes, which cuts cost and widens your supply base.
How: DFMA Services →
The challenge
Older machines run on parts nobody can make again, and each failure stops production.
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What changes
Legacy parts are measured, modeled, and improved, so any qualified shop can make them.
Mining machinery OEMs and startups: we act as your engineering team on crushers, conveyors, and screens.
Your extra design team.
Get Your Free RoadmapMine operators: we define and design the machines your duty needs, then work with your builder on them.
Your mine, our design.
Get Your Free RoadmapMine and machine builder in one loop, so wear, fatigue, and throughput are designed in from the start.
One loop, both sides.
Get Your Free RoadmapBring your own manufacturer, or work with our partner network. We take the designs we engineer as far as you need. We don't manufacture, so we never compete with the OEMs we partner with.
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 machine design with the wear and fatigue data behind it, ready for your builder to quote.
02
FEA and fatigue results you review and approve at each gate, before anything is built.
03
You own the IP by default. When an OEM or partner manufacturer is involved, the contract spells out who owns what.
04
If we missed it in our QC, we fix it. If your supplier can't make the part within three years, or supply dries up, we fix that too.
You send
What we need to start
CAD and drawings, or the parts themselves
Loads: duty, payloads, and cycle data
Failure history: cracks, wear, and downtime
Materials and the processes you use
Targets: life, cost, or uptime
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You get
What you hold at the end
Design: CAD and drawings ready to build
FEA and fatigue results you approved
DFMA changes with the cost of each shown
Fabrication package, ready to quote
Support through build and start-up
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.
Model impact, plasticity, and contact in frames, buckets, and booms that see loads linear tools miss.
Size it to the impact.
Used For
Impact
Contact
Plasticity
Find resonance and fatigue hot spots in frames, screens, and conveyors before cracks stop the machine.
Stop cracks at welds.
Used For
Fatigue
Welds
Screens
Cut part count and move wear parts and castings to standard processes, so more shops can quote them.
Lower cost per part.
Used For
Wear Parts
Castings
Sourcing
Design crushers, conveyors, and screens around duty and service, with the build managed by our partners.
We manage the build.
Used For
Crushers
Conveyors
Screens
Public benchmark
NIOSH: redesigned mining conveyor chain cut noise 7 dB(A) in lab, no link failures in 6 months (2008).
What it means for you
NIOSH redesigned one part, tested it in the lab, then proved it underground. Our mining equipment design services follow the same steps: redesign, analysis, and tests that show the fix holds before the next build.
The public record shows what the method can do. What it does for your equipment depends on your constraints, and the free assessment tells you.
OEM, mine, or both: we set the model, the builder, and the hand-off.
Scope, priorities, field dates, and approval gates.
Design, FEA, and fatigue analysis, checked in our QC.
Drawings and a fabrication package ready to quote.
Build support, start-up support, and later changes.
You approve the design at every gate, so nothing that affects function surprises you. If we missed something in our QC, we fix it. If a supplier can’t make a part within three years, we fix that too.
Same machine failing again? Send the history. Free roadmap.
Kilns, mills, and coolers that run hot, dusty, and nonstop, engineered for heat, wear, and long uptime.
Fewer surprise stops.
Applications
Kilns
Mills
Coolers
High-volume parts and EV systems where every gram and cent counts, designed for the process you run.
Built for high volume.
Applications
Castings
EV Systems
Modules
Aerospace to data centers: see how one engineering team solves hard constraints across ten industries.
Find the one like yours.
Industries
Aerospace
Mining
Data Centers
Fixed 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
Gold · One project: a frame, bucket, or wear part that keeps failing in the field.
Platinum · Ongoing work: engineering support across a fleet of machines.
Diamond · A long program: a dedicated team for a new machine or major upgrade.
FEA, CFD, CAD, DFMA, and testing under one roof. Engineering is a team sport, and you get the whole team.
One team, every skill.
Under One Roof
FEA
CFD
CAD
DFMA
Testing
Veteran-owned SDVOSB status gives defense and federal buyers a set-aside path to proven engineering.
Verify our SDVOSB status.
Credentials
SDVOSB
VOSB
CAGE 8ZK73
NAICS 541330
Missed something in our QC? We fix it. Supplier can't make the part within three years? We fix that too.
Support for the long run.
We Fix
Our QC Misses
Supplier Gaps
Supply Chain
We price to the value we deliver, not hours logged. You buy a design that works, not more iterations.
Pay for the result only.
Collections
Gold
Platinum
Diamond
What do your mining equipment engineering services cover?
Our mining equipment engineering services cover the analysis and design work heavy machines need to survive the field. Most fleets feel the gaps as cracked frames, broken buckets, and wear parts that cost too much. Each of those problems starts in the design, before a machine reaches the pit. Rock impact and overloads bend frames and crack welds. Cyclic loads grow fatigue cracks until a boom fails in service. Every stop far from a shop costs output. Mines also work under MSHA safety standards, so a failed machine is a safety issue, not just a cost. Fixing it after the fact costs far more.
Nonlinear FEA sizes frames, buckets, and booms for impact and overload. Vibration and fatigue analysis find the weld details where cracks start. Mining machinery design in CAD turns those findings into parts that are strong where they need to be. DFMA moves wear parts to processes more shops can quote. Reverse engineering brings legacy parts back to supply. You approve each change before it is built.
Can you fix a part that keeps failing in the field?
A part that keeps failing in the field is telling you something about its loads. Our mining equipment engineering services start with that evidence: failed parts, photos, crack locations, and how often each failure happens. That history often points to the cause faster than any new test, for less. Most repeat failures come from loads nobody measured, details that concentrate stress, or materials picked for cost over duty. Swapping in the same part only resets the clock on the next stop. On haul trucks and loaders, a repeat failure is also a hazard: MSHA requires written safety programs for surface mobile equipment.
We model the part in FEA under the real duty, confirm the cause, and design the fix. Often it is simple: a better weld detail, a larger radius, a stiffer section, or a tougher material. Each fix is checked so the failure doesn't just move somewhere else. You get updated drawings ready to build, and our QC checks every fix before release. Field checks are planned if needed.
Can PPS work with our OEM or manufacturer?
Yes. Mining equipment engineering services from PPS fit the partnerships that are normal across the mining industry. We work in one of three models. As your OEM partner, we act as your engineering team. Operator-led, we design the machine and work with the builder you choose.
When design, build, and test sit with different companies, problems pass back and forth. The builder works from an old drawing, and each party defends its own scope. The Department of Defense's IPPD Handbook organizes programs around integrated product teams for this reason. In a joint program, the mine and the OEM work with us in one loop.
We engineer the design and coordinate the builder in one loop. Bring your own manufacturer, or work with our network of fabricators, machine shops, and test labs. You decide how far we take the design, up to the start of production. We never run production, so we never compete with your OEM. NDAs cover every party, and you own the IP by default, set in your contract.
What do you need from us to start?
To start a project with our mining equipment engineering services, send what you have, in any format. That usually means CAD and drawings, or the parts themselves, plus the duty, payloads, and cycle data. Add failure history with photos, the materials and processes you use, and your targets for life, cost, or uptime. Old drawings help too. Missing data is the most common reason engineering projects stall, because a model built on guessed inputs gives a guessed answer. That is why we don't start the work until every data set is in.
Once it is, the first step is a free assessment of your project scope. We confirm what the work can and can't answer, and tell you what is still missing. Then we send a roadmap proposal with scope, targets, and approval gates. Every project is scoped on its own, so the roadmap sets the schedule, not a stock promise. NDAs are available before you share any files. For gaps in material data, NIST material measurement data is a good first stop.
Who owns the design and the models?
You own the design, the drawings, and the models from your mining equipment engineering services project by default, as set in the contract. With an OEM involved, the contract says who owns what. Some firms keep the models, or license them back to you, so every later change sends you back to them. That locks your product to one vendor and makes design reviews harder, because your team can't open the evidence behind the decisions. You receive the native CAD, the drawings, the simulation model files, and the documented results. Your engineers can then check the work, rerun a load case, or hand the package to a supplier or customer.
We sign mutual NDAs before any of your data is shared, and your files stay in our controlled project folders while we work. If your program has export-control or customer data rules, tell us at the start and we will set up the data handling to match them. For defense programs, the State Department ITAR guidance sets the rules we follow.
What happens if a prototype fails in test?
If a prototype fails in test, we find out why and fix the design. Hard engineering carries unknowns on any project: real loads, material lots, and assembly effects never match a model perfectly. With mining equipment engineering services from PPS, you approve the data at each gate. A test result is then checked against predictions you have already seen, not a black box. A failure in test is data. It shows which assumption was wrong: a load, a material property, or a boundary condition. That data improves the model and the design.
When testing is in scope, we plan the test to confirm the margins that matter most. Then we correlate the model to the results, following ASME verification and validation practice. If the miss was ours, because something slipped through our QC review, we fix it. If the test uncovers a condition nobody knew about, we scope the change with you and update the roadmap. Either way, you get a clear answer and a path to a design that holds.
How are mining equipment engineering services priced?
We price mining equipment engineering services to the value they deliver, not the hours we log. Hourly billing rewards extra iterations, so the cheapest quote often becomes the most expensive project once tooling, rework, and field failures show up. Our incentive is to get the design right the first time. We engage by fit, not as a ladder. 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.
Gold is never required, and some clients start at Platinum or Diamond. These are starting points, not quotes; your roadmap sets the price. 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. Our engineering consultant pricing page explains how each collection works in more detail.
Frames cracking or wear parts failing early? Send the data.
Send your CAD, duty data, and failure history. We review your project scope in a free assessment and reply within one business day with next steps.
On-site assessments that require travel are quoted separately.