ENERGY
SCALE

Product design and engineering services

SERVICES CONTACT

ABOUT

I'm Sean Casey, a mechanical engineer with 12+ years of industry experience in clean energy technologies and the founder of Energy Scale.

Energy Scale provides product design and engineering services with unique expertise in energy storage and electrochemical product design. From prototype, to product launch and commercialization, Energy Scale offers support at any stage of the product lifecycle.

Let's collaborate to drive your project forward.

CONTACT
R&D SERVICES
  • - Conceptualization and ideation
  • - System modeling and optimization
  • - Analysis and simulation
  • - Design of experiments
  • - Data analysis and automation
PRODUCT DEVELOPMENT
  • - 3D CAD Design and Drafting
  • - Design analysis and simulation (FEA and CFD)
  • - GD&T tolerancing (ASME Y14.5)
  • - Injection molding design
  • - Manufacturing design optimization DFM/DFA
  • - Jig and fixture design for manufacturing
  • - Failure analysis and root cause determination
  • - Cost reduction strategies
ELECTROCHEMICAL EXPERTISE
  • - Reactor and balance of plant design
  • - Electrode selection and design
  • - Process and instrumentation documentation
  • - Sensor integration and selection
  • - Test stand design
  • - Material compatibility testing
  • - Certification assistance (UL 9540 & UL 1973)

SERVICES

A range of services for all stages of the product lifecycle from ideation to commercialization.

CAD DESIGN AND DRAFTING

Turn ideas into 3D models and drawings. Expert at applying GD&T ASME Y14.5 and analyzing tolerance stacks.

FEA and CFD

Analyze designs using 3D simulation software such as ANSYS mechanical, Fluent, and OpenFOAM.

ELECTROCHEMICAL AND ENERGY STORAGE

Design of electrochemical systems from reactors and cell design to balance of plant integration. From lab scale prototyping and test stands to commercial product design.

INJECTION MOLDING DESIGN

Convert parts from high-cost CNC machining to low-cost injection molding. Consolidate multiple parts into one. Improve assembly using design features such as snap fits and inserts.

SYSTEM MODELING

Optimize systems and reduce cost through system modeling and trade-off studies. Multiphysics models that can give unique design insights.

COST REDUCTION

Design simplification and system redesign for low-cost manufacturing and assembly.

CONTACT

Reach out to see how we can collaborate and drive your projects forward.