Low volume manufacturing

EnCata has the necessary engineering capabilities and expertise to produce a technically efficient small batch before your market launch. To create these test batches, we use reasonable 3D printing technologies, such as FDM, SLA, and SLS. Our team also has proficieny in plastic injection molding, and is eager to engage in low volume production of your first batch using this technology.

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Producing a small batch with EnCata is

We are committed to delivering a product that has been meticulously optimized for both economic feasibility and your specific business goals. To ensure seamless production, we provide you with a detailed list of approved component suppliers and mass producers, all capable of manufacturing the required quantities efficiently. With our production facility conveniently located under the same roof, we can produce your batch in the shortest time possible, minimizing delays. Our extensive experience across 20+ industries allows us to meet the highest quality standards, ensuring that we understand and can adhere to the specific requirements of your sector.

01

Cross-Industry Expertise

Throughout its existence, EnCata has implemented projects across 20 different industries, many of which have integrated multiple sectors. This diverse experience enables us to tackle unique, market-defying solutions, which you can also find in our portfolio.

02

15 Years of Experience

Our extensive experience allows us to offer solutions based on proven concepts, not just theoretical knowledge. By choosing us for development and manufacturing, you benefit from the services of highly qualified engineers and 300,000 hours of experience.

03

Full-Cycle Development Under One Roof

Time is a valuable resource in new product development, which is why we have brought our engineering teams together under one roof. This allows projects to be developed under the direct supervision of a project manager, speeding up the process and making it more manageable.

Want to know more about our expertise?

Fill out the field using the button below, and we will send you a presentation of all our projects not under NDA, within which we conducted rapid prototyping.

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Product Development Technology Stack

• 3D-printing
• Composite forming
• Injection molding
• Milling
• Lathe
• Lather cutting
• WaterJet cutting
• Metalworks
• EDM
• Welding
• Bending
• Molding in silicone forms
• Polishing
• UV-printing
• Electrodeposit coatings
• Reverse engineering
• 3D drawings and engineering documentation
• 3d modeling and assemblies
• Painting
• Vacuum forming
• Design for manufacturing

Featured Projects

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

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8K VR Headset for Sports

EnCata developed an 8K VR headset for sports training which featured ultra-high resolution, a wide field of view, and compact dimensions. It allowed real-time interaction between players in different places. The prototype was ready for pilot production in just 8 months.

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Custom Brain Cooling Device

EnCata developed a dual-circuit brain cooling system for therapeutic use in stroke rehabilitation, neurotrauma, and psychiatric care. The system includes a portable cooling control unit and a head-cooling helmet.

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Custom Soil Testing Equipment

EnCata provided engineering services for a startup developing a custom soil testing rig with a stabilometer and load system. We delivered mechanical engineering, CAD, FEA, prototyping, and documentation. Built and tested from scratch in just 5 months.

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Custom Atmospheric Water Generation System

This custom-built system extracts up to 50 liters of water per day from air in hot, dry regions. Developed to meet a specific customer's needs, it showcases EnCata’s full-cycle expertise in thermal design, electronics, firmware, and prototyping. All IP belongs to the customer.

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Custom TPMS Test Stand for Industrial Use

EnCata engineered a custom tire pressure sensor (TPMS) test stand for industrial QA—developing mechanics, electronics, and firmware from scratch. The compact device supports 10 chambers. All IP belongs to the customer.

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Custom Thermal Manikin Testing System

EnCata developed a thermal manikin testing system to evaluate fire-protective clothing. The system features high-efficiency thermal panels, a mobile manikin with 180° rotation, and a crane-beam mechanism adapted to the facility’s space and ventilation layout.

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Smart Soil Irrigation System Development

EnCata helped a startup develop a smart soil irrigation system from concept to MVP. The system includes custom electronics, BLE, LoRaWAN, and solar-powered modules for real-time soil monitoring and control. Built and tested in just 8 months.

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Actuator Spinner Development

EnCata developed a hand-operated kinetic toy with a custom actuator mechanism that converts axial pressure into controlled rotation. We delivered the full mechanical product development cycle – from concept and ball screw design to TRL-7 prototype.

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Autonomous snooker robot

The autonomous snooker robot is a device that serves as a trainer during a game of pool. The robot can work as a trainer, against a human, or in tandem with them. The kicking mechanism replicates a human kick's dynamics.

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Blood Container

EnCata developed a custom medical container with a separator and filtration system for centrifugation, from concept to TRL 7 prototype. The project involved engineering under strict healthcare standards and tolerances.

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The house-building system “Ecocube"

EnCata engineered the Ecocube modular house-building system that allows for constructing houses from sustainable materials. We applied FEA to improve manufacturing speed by 45%, enabling fast, eco-friendly, and cost-efficient mass production.

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5-axis CNC machine

EnCata engineered a compact, high-precision CNC prototype for machining intricate parts from non-ferrous metals, waxes, and plastics. The CNC machine delivers tight tolerances on small parts and offers low prime cost as its key competitive advantage.

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CFD & FEA for a Copper Smelter Furnace

EnCata carried out advanced CFD and FEA simulations to help an industrial manufacturer analyze heat and gas flow in a copper smelting furnace. The insights revealed inefficiencies, guided geometry improvements, and supported modernization across TRL 1–9.

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A system for analyzing the parameters of the vessel's movement

EnCata provided mechanical and electronics engineering services to design and prototype a modular waterproof enclosure (IP-67) for marine navigation.The system analyzes a vessel’s movement data and the hydrometeorological situation to improve navigational safety.

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Waterproof Antenna Enclosure Design

We developed a waterproof enclosure for a UHF antenna used in ship navigation and UAV control. The system is mounted up to 50 m underwater. EnCata delivered industrial design, mechanical engineering, and a working prototype. All IP belongs to the customer.

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Wearable medical smartwatch

EnCata engineered a wearable medical smartwatch with HR, HRV, and SpO₂ monitoring plus GPS, Wi-Fi connectivity. The system tracks vital signs and alerts doctors if health declines. The project spanned electronics, mechanical design and firmware development, leading to 10 MVPs.

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MVP for Smart Wellness Chair

EnCata helped an early-stage health tech company develop a custom reclining pod MVP – a smart wellness hardware solution designed for workplace recovery zones. Our team handled structural analysis, actuator-driven kinematics, and full-cycle mechanical prototyping.

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Aerocapsule for noise-insulation in the crowded places

EnCata developed a smart soundproof booth for comfort and privacy in noisy public spaces. The system features HVAC automation, IoT sensors, and showcases our expertise in mechanical design, electronics, and smart systems engineering.

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Electric skateboard for urban mobility

We helped an electric mobility startup turn a raw prototype into a smart, IoT-connected skateboard for city commuting. The device is a reliable, eco-friendly, convenient, and intelligent type of urban transport with the possibility of integration into urban infrastructure.

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Compact horizontal drilling tool

EnCata engineered a compact horizontal directional drilling system for trenchless pipe-laying. The full-stack solution integrates mechanics, hydraulics, and electronics to create pilot boreholes with precise control.

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IoT powered rodent detector

EnCata engineered an IoT rodent detection system with movement sensors and NB-IoT data transfer. The system detects rodent activity and sends data to the cloud. The project spanned from electronics design and 3D modeling to prototype development and a 10-unit pilot batch in 6 months.

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Cuby House Development

EnCata developed a smart prefab housing system from scratch, covering feasibility, modular design, HVAC, structural simulations, and IoT integration. The project focused on reproducibility, scalability, and reduced labor in construction.

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MVP of Smart Disinfection Gate System

EnCata developed a custom smart disinfectant gate in response to COVID-19-related challenges. The system was engineered from scratch and tailored to meet public health and safety needs through embedded control, modular architecture, and robust stainless-steel design.

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VR surgery training and simulation platform

EnCata engineered a custom VR surgery training system with motion tracking and haptic feedback. We developed the platform from scratch and helped the client validate the concept with rapid prototyping.

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Custom Surgical Drain Device

EnCata supported a MedTech startup as an engineering contractor by developing a custom surgical drain device intended for post-operative pleural cavity drainage. The project included mechanical design, rapid prototyping, and low-volume manufacturing. All IP belongs to the customer.

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IoT-powered CRM and ERP Software Platform for Manufacturing

EnCata developed a custom IoT-powered ERP and CRM platform for a fabrication lab that integrates ERP hardware and an inventory management system. Our team delivered a scalable makerspace management solution that reduced operational costs and improved user experience.

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Blockchain-based fund asset control system for issuing vouchers

A blockchain-based solution to control and manage three-party (service provider / donor / end-customer) contractual engagements. The voucher issuance system incorporates smart contracts and automates document flow, reducing overheads for all parties involved.

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Digital fab lab to incubate hardware startups

EnCata delivered feasibility study, prototyping, and engineering services to build a digital fabrication lab. We integrated advanced equipment and IoT systems, turning an empty space into a prototyping ecosystem that supports hardware startups.

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Educational platform MakeIT School

EnCata conducted a feasibility study and delivered hardware development for the MakeIT educational platform that introduces students to prototyping and engineering. The platform helps schools adopt STEM programs and gives students practical experience in hardware engineering.

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Industrial Gas Burner CFD

A startup developed a novel ceramic gas burner capturing IR radiation for higher efficiency. EnCata validated the concept with industrial computer simulations and CFD modeling, proving 84.9% efficiency after 300+ experiments.

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Custom Smart Beverage Pourer

EnCata supported a startup as an engineering contractor, developing a smart beverage pourer for bars that meters each pour in real time, connects to POS and mobile apps, and enables NFC payments — from PoC to MVP. All IP belongs to the customer.

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AI-driven tools tracking system

EnCata engineered an AI-powered tool tracking system which combines 5S boards with machine vision to monitor tool usage in real time. Integrated with ERP/CRM software, it improves accountability and reduces losses. Our team took the project from concept through to a working IIoT solution.

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Grain temperature monitoring system

EnCata engineered a grain temperature IoT system with stainless-steel spear sensors and RS-485 networking. The solution went from R&D and prototyping to a 200-unit batch in 2 months, helping the client improve crop storage control.

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Explosion-proof industrial baghouse for dust collection systems

EnCata engineered and manufactured a custom ATEX-compliant explosion-proof baghouse for a sugar processing plant. The system filters 32,000 m³/h of dusty air, integrates smart PLC controls, and meets strict IIIB explosion safety standards.

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Explosion-proof industrial vacuum cleaner

EnCata engineered and manufactured a custom ATEX explosion-proof industrial vacuum cleaner for sugar dust removal. Our services included mechanical engineering, DFM, FEA simulations, and integration into the mill’s central cleaning system.

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Self-managed cold electronic storage for digital assets custody

EnCata developed a custom electronic storage vault for a fintech customer, integrating over 8,194 Spark™ wallets. The vault enables secure storage and blockchain-controlled transactions. We delivered enclosure design, DFM, and a functional prototype.

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Inflatable Building Development

EnCata designed and built a smart inflatable facility to expand its R&D space. The project included pneumatic structural design, HVAC, embedded IoT systems, cloud-based control, simulations, and manufacturing — delivered from concept to commissioning in 3.5 months.

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Autonomous Drone Station

EnCata delivered UAV engineering services, designing and manufacturing an autonomous drone docking station with charging, climate control, and positioning systems. The product supports surveillance, delivery, and inspections in Arctic to desert conditions.

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Fourier Spectrometer

EnCata helped a laboratory equipment company develop a Fourier spectrometer – a device for analyzing the spectral composition of light in analytical measurements and healthcare diagnostics. The project cut BOM costs by 24%, reached TRL-8, and resulted in a patent.

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Urban Farming IoT System for Plant Growth

EnCata engineered a smart farming IoT system that automates plant growth with sensors, custom PCB design, and cloud control. The solution developed and prototyped by our team helped the client to validate technology, secure patents, and prepare for market entry.

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Laminar flow box for GMP production line

EnCata provided medical device engineering services to design and prototype a custom laminar flow box for a GMP production line. The product features cleanroom-compliant design and precise airflow control for sterile manufacturing.

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Custom Warehouse Fulfillment Robot

EnCata supported a robotics startup as an engineering contractor, developing a custom warehouse robot (400 kg load) for indoor and outdoor use — from concept to pilot-ready prototype. All IP belongs to the customer.

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Custom IoT 5-in-1 Air Purifier

EnCata developed a multifunctional IoT device that purifies, humidifies, ionizes, and monitors indoor air. We supported a consumer startup as an engineering contractor — from concept and embedded software to pilot production. All IP belongs to the customer.

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Custom Smart Kitchen Kettle

EnCata developed a smart kitchen appliance for a European company entering the smart home market. We delivered feasibility studies, electronics, firmware, and a working prototype for a device that brews coffee, tea, and prepares baby formula.

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Digital transformation and feasibility study in construction

EnCata helped a major European construction company carry out a digital transformation and feasibility study. We researched available IoT solutions and modeled ROI. The project resulted in a clear roadmap for smarter building management and service optimization.

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3D body scanner

EnCata engineered a 3D body scanner for the fashion retail industry which enabled accurate body measurement and real-time 3D modeling. In just 6 months, our team helped the client transform a concept prototype into a batch-ready product.

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Truck Variator

EnCata delivered mechanical engineering and prototyping services for an academic inventor and helped prove the truck variator’s frictionless transmission principle. In just 5 months, our team moved the project from a raw idea to a tested prototype that demonstrated technical feasibility.

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VTOL impeller design

EnCata engineered a VTOL impeller that increased thrust by 24.6% through CFD simulations and aerodynamic optimization. We optimized the efficiency of multirotor three-bladed propellers within an impeller ‘barrel’ geometry, followed by DFM for production readiness.

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Sludge Recycling Feasibility Study

EnCata delivered a sludge recycling feasibility study in Oman, assessing six treatment technologies and CAPEX. The study shaped the plan for a waste disposal plant with 100 tons/day sludge capacity, providing the client with clear technical and business guidance.

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Custom IP66 Enclosure Design

EnCata developed a custom IP66-rated enclosure for automotive electronics, tailored to a specific PCB. We handled industrial design, DFM, in-house mold fabrication, pilot production, and assembly, delivering full-cycle development under one roof.

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Custom IIoT Solution for Thermal and Water Flow Control

IIoT solution combining thermal metering, flow regulation, and smart valve control. Built from scratch (TRL 1) and deployed in real infrastructure (TRL 9). All IP belongs to the customer.

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Hydroponics IoT Plant Pot

EnCata engineered a smart hydroponics IoT plant pot that automates plant care through nutrient dosing, using sensors and cloud control. We delivered industrial design, CAD models, BOM, and specs to help the client move from lab research to a market-ready device.

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Custom Smart Beverage Pourer

EnCata supported a startup as an engineering contractor, developing a smart beverage pourer for bars that meters each pour in real time, connects to POS and mobile apps, and enables NFC payments — from PoC to MVP. All IP belongs to the customer.

View more

Actuator Spinner Development

EnCata developed a hand-operated kinetic toy with a custom actuator mechanism that converts axial pressure into controlled rotation. We delivered the full mechanical product development cycle – from concept and ball screw design to TRL-7 prototype.

View more

Custom Surgical Drain Device

EnCata supported a MedTech startup as an engineering contractor by developing a custom surgical drain device intended for post-operative pleural cavity drainage. The project included mechanical design, rapid prototyping, and low-volume manufacturing. All IP belongs to the customer.

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Hardware DevelopmentElectronics DevelopmentFirmware DevelopmentMechanical EngineeringComputer SimulationsIndustrial DesignDesign for ManufacturingRapid PrototypingFeasibility StudiesLow Volume Manufacturing

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