FEA engineering services

The finite element analysis (FEM, FEA) is one of the essential tools at EnCata for carrying out stress-strain, heat transfer, structural and thermal analysis. The finite element method also helps solve basic thermodynamics, including heat flow analysis.

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Finite element modelling

We routinely employ the finite element method on our in-house computational facilities and, when needed, have direct access to research supercomputers of our partner. Although FEA is not a solution for everything, it is another useful modern tool. It allows for relatively quick and resource-saving testing of new design ideas, benchmarking them, and performing technical fine-tuning of existing concepts. Employing FEA minimizes the number of real-world prototypes and testings necessary to achieve desired characteristics. Virtual testing of new products can also help verify whether and if they comply with given national or international standards.

Finite element simulations provide insights into what and why will be happening with new products under completely different conditions.These might be situations when a new product is dropped on a floor or  heated up to extreme temperatures, a new building suffers from earthquakes, or a product or its parts undergo deformations. Such new insights and understanding empowered by the experience of EnCata’s engineers significantly accelerate the development of a new product. In addition, knowledge-driven choice of solutions ensures implementation of the most suitable ones in the end-product, keeping in mind such product properties as its functionality, price, durability, etc.

60+ Engineers

We act as your extended R&D team which is faster than hiring engineers locally. The breadth of our technical expertise is unique.

Development Speed

Our dedicated team is ready to scale up quickly. We utilize AGILE lean development process that leads to 30-50% faster delivery.

Burn rate


Our development location enables us to be cost-effective and deliver premium R&D and engineering services at 1/3 of the price compared to that of in N-W Europe and USA.

Finite Elements Analysis Simulation

Similar to CFD, Finite Elements Analysis simulation can be used to perform sets of virtual certification experiments and quickly design updates if necessary before proceeding with physical prototyping and certification tests.

Based on the knowledge and experience of our engineers, EnCata offers  FEA static and dynamic analysis, modal analysis, stability, rotordynamic analysis and vibration analysis and acoustic analysis. We also employ the finite element method in heat transfer analysis and thermodynamics simulation.

mechanical engineering DFM

Mechanical Engineering

Mechanical Engineering is not only about the development of products that will be mass-produced, but includes both Components design and Enclosure design and development.  Therefore, starting new projects, we always consider these two parts of a Client’s product.

FEA and CFD simulations

Computational Fluid Dynamics (CFD)

Numerical modeling is often used at the first stages of product development. For example, when designing the enclosure, it is important to consider external and internal factors that will subsequently affect the developing device. CFD heat transfer analysis helps check enclosure ventilation design or gather data to choose materials.

Product R&D

Hypothesis testing and the search for non-standard solutions take place at the R&D stage. The use of the finite element method makes it possible to obtain new information about the research object much faster. The finite element analysis model could be a digital subject of the research.

Proof-of-Concept Prototyping

The proof-of-concept stage is a good start for new product development. The design of a proof-of-concept prototype is not as simple as it can seem at first glance. The key point here is prioritizing functions to be cost-effective. POC prototype could be used to verify a finite element analysis model.

Reverse Engineering

Using RE gives apparent benefits for any product design company. You save time and reduce costs since you are not reinventing the wheel during the design stage. Fluid flow simulation could support RE and provide a better understanding of the system under review.

Feasibility Studies

It is important to understand what benefits new product features will give your business and how they affect financial performance. Our engineers could conduct a technical analysis of competitors. Our product design consultants will calculate the preliminary financial indicators to make informed decisions.

Finite elements in product analysis and design

We used FEA in almost every project when dealing with mechanics. The FEA helps design engineers reduce product development time and cost.Our design engineers use FEA as a design tool during the industrial structures design and analysis because it allows them to find insights about their solutions without prototyping. Analysis of easily modifiable CAD models provides quick turnaround times and ensures prompt implementation of changes. Successful use of FEA requires an understanding of FEA basics and commonly used modeling techniques. Our design team works with inherent errors and their effect on the quality of results. 

One of the most frequent cases when we use FEA at EnCata, is mechanical analysis in SolidWorks. Different loads are being applied on a given object or objects, examining the resulting deformation patterns. We use FEA heat flow analysis for simple cases and prefer CFD for complex systems.Not only that, knowledge-driven choice of technical solutions ensures implementation of the most suitable ones in the end-product, keeping in mind such product properties as its functionality, price, durability, etc.

How To Do Applied Finite Element Analysis With EnCata?

The finite element analysis (FEA) process consists of standard steps. However, the efforts depend on the initial data and system complexity.The engineer should initially import CAD, usually SolidWorks, 3D model to the FEA software.The next step is meshing the model. Meshing affects the quality of results, calculation duration, and risk of errors during analysis.Then, we need to assign material properties. For innovative materials, preliminary laboratory testing should be necessary.After that, the engineers will apply boundary conditions and loads. They scrutinize new product use cases to make the right assumptions.The engineer sets up the determinative parameter and runs it to obtain results. The results should be examined.Finally, our engineer writes a report or makes an informed decision for an update.

Product Development Technology Stack

PCBA design

Finite element analysis in SolidWorks

Battery management icon

Heat transfer analysis
Loads and deformation analysis

Thermal analysis
Structural analysis

Engagement Models

We focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

Some hardware Projects we delivered

Work that highlights the incredible technologies, solutions, and products EnCata developed.

Industries We serve

Our hardware engineers are focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

FAQ related to Product development

At EnCata, what kinds of contracts do you use? Is it a fixed-term or an agile contract?

EnCata works with both fixed term and agile contracts.

What should I do now that I've approached you with my project idea?

1. Once you have approached us with the project, we conclude the NDA and send the information to the Sales Manager for further evaluation and project planning.
2. The Sales Manager or Sales Engineer will contact you to clarify your goals, requirements and tasks to accomplish. This process is very close to business analysis. When the details are agreed with you, a cost estimate and a quotation are prepared.
3. If you accept the quotation, we will prepare a Technical design specification to document scope of work and requirements and conclude an agreement.
4. After we've signed the agreements, we'll assign you a Project Manager who will gather a project team and report on the project progress.

Can you provide me with a certification of competence?

EnCata employs around 30 engineers with Master's and PhD degrees in electrical and industrial design, mechanical engineering, prototyping and manufacturing from European universities. Each employee is an expert in his or her field.

What level of training do your specialists have?

The majority of specialists are of middle or senior levels. Their range of influence is broad enough to encompass the entire new product lifecycle. Our specialists resolve legal and certification difficulties during the concept stage, optimize production costs during the 3D model development process and create necessary documentation for firmware support. Juniors make up only 15% of the team. They constantly upgrade their qualifications under the supervision of seniors.

Is it possible for us to cooperate with EnCata’s team?

EnCata is always willing to work with its client. We have everything we need to create a collaborative site. Both parties can work on the project simultaneously. The Customer, for instance, and his/ her team designs the electronics while we work on the enclosure. When teams work together to achieve a fantastic result, it is always a win scenario.

Is it possible to discuss the project with your technical team?

EnCata’s team is always willing to discuss all the necessary details about the project proposed. Our full-fledged team of professionals will interrogate you until both parties are satisfied with the procedures necessary to complete the job.

Can EnCata facilitate mass production?

It certainly can. For any product, EnCata creates a design documentation package and a process documentation package that is suited to the production. It should be noted, however, that the technologists at the customer's chosen plant may make changes or impose their own requirements on the documentation design. EnCata, in turn, makes it easier for the client and the technologist to communicate. EnCata does not mass produce, although it can undertake small-scale production at the request of customers.

Do you sign NDAs?

Yes. As a highly professional design and engineering firm, we make sure that all discussions with our clients and all information regarding your invention, idea and other proprietary information are kept confidential.

Patent or Develop first?

We follow a LEAN approach in product and business development and thus we strongly recommend patent filings only after you are  at least part-way through development. This is because patenting is expensive and early patents can already become obsolete or irrelevant later in the development phase. Typically, EnCata's work generates many patentable opportunities for our clients  and the best strategy is to file patents at TRL-7, i.e. when early beta prototype is ready and when a startup is ready to start batch production and marketing.There is, however, another strategy, which is to use provisional patents which can be loose and are not to be disclosed to the public for 18 months. These are much less expensive and time consuming, generally costing below $500.

EnCata will always sign a Non-Disclosure Agreement and keep your intellectual property confidential during the development phase and then we can recommend several third-party patent attorneys when the time is right.

Does EnCata outsource electronics services?

Our in-house professionals handle almost all electronics work, including interface design, protocol development, communication design, schematic design, PCB Design, Firmware design and battery management. If the Customer requires a service that Encata does not supply, we have partners that can meet that need.

Do you write program code, either software or firmware?

We certainly do. EnCata employs electronics specialists who deal with low-level firmware. We also have experts on staff who can implement high-level software code.

Are there hardware engineers in your team?

EnCata employs 12 mechanical and industrial designers and 10 electrical engineers with experience in hardware and firmware. Our team consists of middle and senior level engineers, who have 5+ years of field expertise and have already completed more than 300 projects.

Can EnCata help me with fundraising?

We do indeed help with fundraising through our large business network. However, we typically recommend startups to our partner VCs after we have done some work for the startup and learned more about the team and their core technology. This feedback and recommendation is of great value to all of the friendly VCs as it saves them much time and effort for due diligence.

Have a project to do? Reach out to EnCata team

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