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Our Services

Mechanical Engineering Design Services

Product Development Engineering Services

Custom Machine Design

Predictive Maintenance

Forensic/Failure Analysis

Rusco Engineering provides the engineering expertise needed to develop a new product or improve an existing one. The following steps define the typical product design process.

Concept Generation

The first phase usually begins with an idea for a new product. A product specification is developed to define the functions and performance criteria for the product. Depending upon the product, one or more industrial design sketches are created to define the visual appearance features.

Detail Design

The second phase is to develop a desing based upon the concept model and specification. The design is developed using SolidWorks. This virtual prototyping allows for interference checking and range of motion studies before any physical parts are made. Parts are designed with consideration to how they will be manufactured, assembled and used.


As the physical shape is being developed, the design is evaluated from an analytical standpoint to ensure there will not be any performance issues. The analysis to be performed varies depending what is being designed, but may include things such as stress or thermal analysis. These canbe hand calculations, or if needed, FEA.


Once the design is completed, prototypes can be built. Plastic injection molded parts can be quickly simulated. It multiple parts are required, a silicon mold can be made and urethane cast parts can be made. For fabricated parts, detail drawings are created and sent to machine shops.

Assemble and Test

Components parts are assembled and tested to ensure the product meets the performance specification. If changes are required, drawings are updated and the prototype phase is repeated.

Product Release

The final phase is to release the product for production.