NESTech CAD Service - Customer Case Studies

⚙️ INDUSTRY 4.0 | MACHINE TOOLS

High-Precision CNC Excellence 12+ Years of Engineering Partnership

A renowned German manufacturer of high-precision CNC machine tools, turning centers, and milling machines partnered with NESTech for over 12 years, supported by a dedicated team of 25+ engineers.

🔧 Engineering & Product Development Support

Executed multiple projects as an extended product engineering team, supporting new product development and design initiatives across various machine tool platforms.
Implemented innovative design enhancements across multiple series of CNC machine tools, involving advanced 3D modeling and management of large-scale assemblies using leading CAD platforms.
Developed highly complex casting models using specialized foundry-oriented modeling techniques, including:
- Creation of foundry-ready casting models with appropriate draft angles
- Addition of machining allowances in critical areas
- Core modeling for casting manufacturability
- Generation of final machined models by deriving them from the foundry models through machining cut operations

🎬 Visualization & Marketing Support

Created high-quality product animations to demonstrate new machine functionalities and product features.
Delivered photorealistic product renderings for use in marketing materials, catalogs, brochures, and product launches.

📄 Technical Documentation

Provided comprehensive technical documentation and manual creation support for various machine tool products and assemblies.

🌍 Manufacturing & Supply Chain Support

Supported contract manufacturing initiatives by assisting in sourcing high-quality castings from India for export to Germany.
Coordinated critical machining operations and supplier interactions to ensure compliance with stringent German quality and manufacturing standards.

Duration 12+ Years

Team Size 25+ Engineers

Domain CNC Machinery

🚜 HEAVY EQUIPMENT | AGRICULTURE & CONSTRUCTION

Global CAD Transformation & Engineering Excellence 12+ Years Partnership | Germany & USA Operations

A premier American corporation specializing in agricultural, construction, and forestry machinery partnered with NESTech for over 12 years across its operations in Germany and the USA, supported by a dedicated team of 50+ engineers.

📐 CAD Migration & 3D Engineering Support

Successfully converted more than 200,000 legacy 2D CADAM drawings into fully parametric 3D models with associative, production-quality 2D drawings.
Supported large-scale engineering transformation initiatives involving complex product data migration and standardization across multiple product lines.

⚙️ Product Design & Component Engineering

Worked on a wide range of complex components used in agricultural and heavy equipment machinery, including:
- Castings
- Plastic components
- Sheet metal parts
Developed and managed family tables and configurable part structures to support product variants and engineering standardization.
Created and maintained standard libraries and supplier part databases for improved design efficiency and consistency.

🏭 Advanced Casting Design Support

Developed complex foundry-oriented casting models using specialized casting design methodologies. This included:
- Creation of foundry-ready casting models with appropriate draft angles
- Addition of machining allowances in critical machining areas
- Core modeling for casting manufacturability
- Generation of final machined models by deriving them from the foundry models through machining cut operations

🌍 Global Engineering Resource Support

Deployed onsite engineering resources in Germany as well as offshore teams in India to support:
- New product development programs
- Engineering capacity expansion initiatives
- Large-scale CAD and product engineering projects
Enabled seamless collaboration between global engineering teams, helping accelerate project execution while maintaining high engineering quality standards.

Duration 12+ Years

Team Size 50+ Engineers

Regions Germany & USA

CAD Conversion 200K+ Drawings

🚆 RAIL & TRANSIT | ELECTRIC DOOR SYSTEMS

Parametric CAD Library & Rail Door Innovation 5+ Years Partnership | Austria-Based Transit Manufacturer

An Austrian-based manufacturer specializing in electrically operated entrance, sliding, and plug doors for high-speed trains, metro systems, light rail vehicles, and buses partnered with NESTech for over 5 years, supported by a dedicated team of 12+ engineers.

📚 CAD Library Development & Engineering Standardization

Built an extensive library of parametric 3D CAD models with fully associative, production-quality 2D drawings organized product-wise.
Initially focused on cataloging standard components and supplier parts, and progressively expanded the library to include a larger proportion of internally engineered components as more products were migrated to 3D CAD platforms.
Established standardized modeling practices and reusable engineering data to improve design efficiency and consistency across product lines.

💡 New Product Development & Concept Engineering

Provided live project support for new product development programs involving electrically operated door systems for:
- High-speed trains
- Metro rail systems
- Light rail vehicles
- Buses and trams
Rapidly developed concept designs for sliding doors, plug doors, and associated retractable step systems while ensuring compliance with the dimensional profiles and operational constraints of different vehicle platforms.

🔧 Detailed Engineering & Production Support

Converted approved concepts into detailed engineering designs, including:
- Individual component design
- Sub-assembly development
- Large assembly integration
- Production-quality manufacturing drawings
Supported the complete engineering lifecycle from concept development to manufacturing release.

📊 Project Scale & Execution

Successfully handled more than 15,000 engineering drawings and contributed to over 25 new product development projects.
Enabled faster product development cycles through dedicated offshore engineering support and close collaboration with customer engineering teams.

Duration 5+ Years

Team Size 12+ Engineers

Drawings 15,000+

NPD Projects 25+

🏗️ HEAVY INDUSTRIAL EQUIPMENT | GLOBAL MANUFACTURING

Enterprise CAD Standardization & Industrial Simulation 8+ Years Partnership | 300,000+ CAD Models Managed

A leading global manufacturer of specialized heavy equipment for road construction, aggregate processing, wood processing, concrete and asphalt production, heat exchangers, industrial burners, and oil rig applications partnered with NESTech for over 8 years, supported by a dedicated team of 30+ engineers and involving the management of more than 300,000 CAD models.

🏢 Enterprise CAD Standardization & Data Management

Implemented enterprise-wide CAD standardization initiatives across multiple business divisions and product lines.
Executed large-scale CAD data migration projects involving multiple legacy CAD platforms and heterogeneous engineering data formats.
Provided PDM-to-ERP integration support services to streamline engineering data flow, improve BOM accuracy, and enhance manufacturing coordination.

🤖 CAD Automation & Customization

Developed customized CAD solutions tailored to customer-specific engineering workflows and standards.
Created CAD macros and automation tools to improve design productivity, reduce repetitive tasks, and enhance engineering efficiency.

⚙️ Engineering Design & Product Development Support

Delivered live engineering design and product development support across a wide range of industrial equipment and machinery systems.
Supported detailed mechanical design activities, large assembly management, and production engineering for complex heavy equipment products.

📊 Simulation & Engineering Analysis

Performed advanced engineering simulations, including:
- Finite Element Analysis (FEA)
- Computational Fluid Dynamics (CFD)
Assisted in validating structural integrity, thermal behavior, fluid flow, and product performance under real-world operating conditions.

📐 Drafting & Manufacturing Support

Created high-quality, production-ready 2D manufacturing drawings in accordance with customer and industry standards.
Supported engineering documentation and manufacturing release processes for global production teams.

🖨️ Simplified Models & Digital Visualization

Developed simplified CAD models optimized for:
- Marketing presentations
- FEA simulations
- 3D printing applications
Performed imperial-to-metric conversion for legacy engineering models and drawings to support global manufacturing requirements.
Created shrink models and lightweight digital representations for marketing displays and additive manufacturing applications.

🎥 Product Visualization & Marketing Support

Produced product animations and marketing animations to showcase machine functionality, operational workflows, and product features for customer demonstrations, exhibitions, and promotional materials.

Duration 8+ Years

Team Size 30+ Engineers

CAD Models 300,000+

Capabilities FEA | CFD | Automation

🤖 ROBOTIC WELDING | INDUSTRIAL AUTOMATION

Robotic Welding Fixture Design & Industrial Tooling 2+ Years Partnership | Canada-Based Manufacturing

A Canada-based manufacturing company implementing advanced robotic welding lines partnered with NESTech for over 2 years, supported by a dedicated team of 8+ engineers.

🔧 Robotic Welding Fixture Design & Development

Designed and developed robotic welding jigs and fixtures for approximately 200 different welding assemblies.
Engineered a large 12-foot-long rotatable welding platform capable of 180-degree rotation, along with multiple modular fixtures mounted on the primary platform to support various product configurations.
Developed robotic welding fixtures for hand rails capable of accommodating multiple product widths and lengths while ensuring repeatability, rigidity, and ease of operation.

⚙️ Engineering Focus Areas

Designed fixtures to minimize manual handling and improve operator safety during orientation and clamping of large and heavy guard rails.
Evaluated center-of-gravity shifts and dynamic moment loads generated during loading, rotation, and welding operations to prevent excessive stress on motors, bearings, and positioners.
Ensured fixtures were sufficiently rigid to eliminate deformation risks during welding processes and maintain dimensional accuracy.
Designed fixtures to avoid interference with robot weld paths, electrical lines, gas hoses, and fiber optic robot dress packages.
Integrated compatibility with robotic positioners and turntables to support optimal down-hand welding positions for improved weld quality.
Incorporated ergonomic considerations to reduce operator fatigue and improve loading/unloading efficiency and throughput.
Followed the KISS (Keep It Simple, Stupid) principle to develop robust, easy-to-manufacture, maintenance-friendly fixture systems while avoiding unnecessary complexity.

📋 Compliance & Manufacturing Considerations

Designed fixture systems in accordance with modern robotic safety standards including:
- ISO 10218
- ISO/TS 15066
Supported risk assessment procedures and engineering documentation requirements for robotic automation systems.
Ensured fixtures were transportable using overhead cranes and forklift systems and capable of handling specified payload capacities safely.

🛠️ Industrial Tooling & Fixture Engineering Services

NESTech provided engineering design and development support for a wide range of industrial tooling and shop-floor equipment, including:
- Welding fixtures and robotic welding tooling
- Assembly jigs and product holding fixtures
- Drill jig templates and precision tooling
- Pipe expanding tools
- Sensor mounting brackets and automation integration supports
- Material handling pallets, racks, carts, and transport fixtures
- Glass holding fixtures and positioning systems
- Modular fixture systems and ergonomic positioning tables
- Tool boards and workstation layout optimization
- Adjustable support stands and maintenance-friendly quick-change fixture systems
- Quality inspection fixtures for precision measurement applications
- Safety guarding and protective shielding fixtures compliant with industrial safety standards

🎨 Specialized Equipment Development - Rotator Fixture for Paint Line

Designed rotator fixtures with load bars capable of:
- Accommodating varying product widths and lengths
- Withstanding rotational and operational loads
- Operating manually with lockable positioning at any angle
- Handling elevated oven temperatures up to 240°F
- Supporting overhead crane and forklift handling
- Holding products only at extreme ends for paint accessibility
Eliminated the need for complex bolting systems, gearboxes, and linkage mechanisms to simplify manufacturing and maintenance.

🦾 Specialized Equipment Development - Welding Fixture Sliding Arm

Developed sliding arm welding fixtures designed for:
- High rotational load resistance
- Ergonomic operation
- Compatibility with overhead crane and forklift transport
- Payload capacities up to 2750 lbs
- Product variant accommodation
- Simple fabrication and assembly using laser-cuttable components

📊 CAE Simulation & Validation

Performed comprehensive CAE simulations on all developed jigs, fixtures, and industrial equipment.
Conducted structural validation and load analysis to verify:
- Fixture rigidity
- Rotational stability
- Payload handling capability
- Fatigue resistance
- Operational safety and long-term durability

🔄 Engineering Workflow

NESTech followed a structured engineering methodology consisting of:
- Brainstorming and Design FMEA
- Concept finalization and 3D model development
- FEA validation and production-quality 2D drawing creation
- Manufacturing support and delivery
- Feedback incorporation and continuous product improvement initiatives

Duration 2+ Years

Team Size 8+ Engineers

Welding Assemblies 200+

Max Payload 2750 lbs

♻️ MATERIAL RECOVERY | RECYCLING PLANTS | SPM

Plant Digitization, Reverse Engineering & Modernization 2+ Years Partnership | US-Based Fabrication Company

A US-based fabrication company specializing in material recovery systems, recycling plants, municipal waste processing facilities, custom conveyors, and special-purpose machinery (SPM) for material recovery, asphalt, and concrete plants partnered with NESTech for over 2 years, supported by a dedicated team of 6+ engineers.

📐 Engineering Design & Drawing Office Support

Provided comprehensive extended engineering design and drawing office support for a wide range of industrial plants and material handling equipment.
Supported ongoing engineering activities including 3D modeling, assembly design, detailing, fabrication drawings, and production documentation.
Delivered production-ready fabrication drawings aligned with weekly manufacturing and shop-floor schedules to support streamlined fabrication and assembly operations.

🔍 Plant Digitization & Reverse Engineering

Conducted 3D laser scanning of existing and aging plant facilities to capture accurate as-built conditions.
Converted scanned point cloud data into detailed 3D digital plant models using shrink-modeling and reverse engineering methodologies.
Reconstructed complete plant layouts and equipment assemblies to support redesign, modernization, and capacity enhancement initiatives.

🏭 Plant Modernization & Capacity Enhancement

Redesigned existing plants to improve operational capacity, material flow efficiency, and maintainability.
Supported modernization and retrofitting projects for repaired and aging industrial plants by upgrading critical systems and improving equipment performance.
Enhanced plant layouts and mechanical systems to comply with improved operational and industrial safety standards.

🛡️ Safety & Equipment Improvement Initiatives

Designed and implemented engineering improvements for:
- Material handling chutes
- Walkways and access platforms
- Safety guards and protective systems
- Conveyor support structures and auxiliary equipment
Improved operator accessibility, maintenance safety, and plant reliability through practical and fabrication-friendly engineering solutions.

⚙️ Conveyor & Special Purpose Equipment Engineering

Supported the design and development of custom conveyors and special-purpose machinery (SPM) used in:
- Material recovery facilities
- Recycling plants
- Asphalt plants
- Concrete production systems
Assisted in optimizing equipment layouts, structural integrity, manufacturability, and operational performance.

🔄 Plant Retrofit & Continuous Improvement Support

Provided redesign support wherever structural, operational, or maintenance-related improvements were required in existing facilities.
Assisted customers in extending plant life through retrofit engineering, equipment upgrades, and process improvement initiatives.
Worked closely with fabrication and production teams to ensure practical, cost-effective, and implementation-ready engineering solutions.

Duration 2+ Years

Team Size 6+ Engineers

Key Capabilities 3D Scanning | Reverse Engineering

Industry Focus Recycling & Material Recovery

Frequently Asked Questions

What makes NESTech different from other CAD engineering service providers?

With over 25 years of CAD/CAE/PLM mastery, NESTech combines deep engineering knowledge across industries with flexible staffing models (offshore, onsite, hybrid). Our technology-led efficiency includes AI validation, digital twins, and secure data handling. We handle complex legacy systems with precision and have successfully delivered migration solutions for all major CAD platforms.

What staffing models do you offer for engineering projects?

We provide flexible staffing models including Offshore, Onsite, and Hybrid engagement models. Our structured two-shift offshore support ensures continuous progress across time zones, helping you quickly scale engineering capacity during peak workload periods and speed up project cycles to achieve tough deadlines.

Which CAD platforms do you support for migration and modeling?

We support all major CAD platforms including SOLIDWORKS, Siemens NX, and Creo for legacy data modernization. Our system-agnostic approach allows us to handle complex legacy 2D/3D file migrations, ensuring full PLM compatibility, data clean-up, metadata enrichment, versioning, and structured archival for future-readiness.

How does your ongoing project support work?

We offer 24/5 offshore support to accelerate delivery during peak workload periods. Our team takes care of design detailing, corrections, and system modernization while your core team focuses on high-value activities. This includes new product development (NPD) support from concept to detailed design, design modifications based on field failure data, and manufacturability optimization.

What engineering standards do you follow for drawings and documentation?

We adhere to ISO, ASME Y14.5, and DIN standards for production-grade drawings. Our expertise includes strong GD&T application for functional dimensioning, weldment modeling with symbol detailing, dimensional tolerances, fits, stack-up analysis, and manufacturability guidelines. We also support vendor parts library creation and centralized CAD libraries integrated into PLM systems.

How do you handle large assembly management with thousands of components?

We efficiently manage and optimize very large assemblies using techniques like lightweight modeling, top-down assembly design, and modular architecture. Our expertise includes simplified representations, zones, skeleton modeling, and assembly management strategies that ensure smooth performance even with thousands of components in complex mechanical systems.

What is your process for legacy CAD data modernization?

Our legacy data modernization process includes migration of legacy 2D/3D CAD files to modern platforms like SOLIDWORKS, Siemens NX, or Creo. We ensure full PLM compatibility for data portability and lifecycle management, along with data clean-up, metadata enrichment, versioning, and structured archival to make your legacy data future-ready.

Do you provide 24/5 support across different time zones?

Yes, we offer 24/5 offshore support to speed up project cycles and help you achieve tough deadlines. Our structured two-shift model ensures continuous progress across time zones, allowing you to quickly scale engineering capacity during peak workload periods without interrupting your core team's workflow.

How do you conduct root cause analysis for product failures?

We perform Root Cause Analysis (RCA) for product failures using advanced FEA, CFD, and empirical methods. Our team then implements redesign and corrective actions for improved field performance, providing continuous design validation support throughout the product lifecycle to prevent recurring issues.

Which industries have you supported with CAD engineering services?

We have successfully supported global customers across heavy machinery, off-road vehicles, material handling systems, and industrial automation. Our domain-specific design and simulation expertise ensures functional, reliable, and high-performance products delivered under tight schedules and strict customer requirements.