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TOOL INC
SHT 01

Sketch to shipped.

TOOL is an integrated product design and engineering firm based in Massachusetts. We partner with startups and established companies to take hardware from concept through engineering, validation and manufacturing, with one team accountable from the first sketch to the production line.

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VIEW ISOASSY 0%
Exploded assembly drawing of a handheld deviceFive parts stacked along an axis: bottom shell, PCB, top cover, coral knob and four screws, with balloon callouts and overall dimensions. Can be toggled to an assembled view.120.030.0Ø2812345
Parts list for the assembly above
No.PartQty
1Screw, M3 × 8 torx4
2Knob1
3Top cover1
4PCB assembly1
5Bottom shell1
TITLE
DESIGN. ENGINEERING. PRODUCTION.
DRAWN BY
TOOL INC, MA
SCALE
1:1
DATE
Sep 15, 2026
SHT 02

Disciplines

Industrial design, mechanical engineering and production expertise under one roof. Design decisions are made with engineering in the room, and engineering decisions are made with manufacturing in mind.

Industrial design

Defining the product.

Form, ergonomics and the details users touch. We begin with how a product fits a hand, a workflow or a bench, then resolve surfaces, color, material and finish into a design that is ready to engineer.

  • User and field research
  • Sketching and form studies
  • CMF specification
  • Appearance models
  • Renders and packaging

Mechanical engineering

Engineering it to work.

Detailed CAD designed for manufacture from day one. Enclosures, mechanisms, seals and thermal management, validated through analysis and proven on prototypes before tooling is committed.

  • Enclosure and mechanism design
  • DFM and DFA reviews
  • Tolerance stack-ups
  • Structural and thermal analysis
  • Prototype builds and test

Production

Manufacturing it at scale.

We stay engaged through tooling, first articles and the initial production runs. Supplier selection, complete drawing packages, first-article inspection and the quality plan that keeps every unit consistent with the first.

  • Supplier and tooling management
  • Drawing and spec packages
  • First-article inspection
  • Assembly documentation
  • Ramp and cost-down
SHT 03

Process

Five stages, with a gate between each.

Each stage ends with a defined deliverable and a sign-off before the next begins. You always know where the project stands, what it will take to move forward, and what you own if you pause.

Bar lengths reflect a typical schedule

0102030405
  1. 01

    Discovery

    Brief, requirements, constraints and a competitive teardown.

    Gate: Product requirements approved

    1–2 wks
  2. 02

    Concept

    Sketches, architecture options and form studies, supported by early foam and printed models.

    Gate: Design direction selected

    2–4 wks
  3. 03

    Engineering

    Detailed CAD, DFM reviews, analysis and working prototypes in production-intent materials.

    Gate: Drawing package released

    4–12 wks
  4. 04

    Validation

    EVT and DVT builds with drop, ingress and life testing. Findings are rolled back into the CAD.

    Gate: Design frozen

    2–6 wks
  5. 05

    Production

    Tooling, first articles, PVT and ramp. We remain on the program until yield is stable.

    Gate: Parts shipping

    Ongoing
SHT 04

Selected work

Selected projects

5 listed

  1. P-241Handheld gas analyserIP67 sealed enclosure with glove-friendly controls, drop-rated to 2 m.Industrial instrumentation, ID, ME, production
  2. P-233Bench-top centrifugeSheet-metal chassis with a molded lid, re-engineered for a 40% reduction in part count.Life sciences, ME, production
  3. P-218Wall-mounted EV chargerDie-cast heatsink body that doubles as the mounting structure. UL listed and outdoor rated.Energy, ID, ME
  4. P-209Wearable sensor clipTwo-shot overmolded housing at 11 g with one-handed attachment. Tooled and ramped in Shenzhen.Health, ID, ME, production
  5. P-197Robotic gripper moduleMachined aluminum fingers with a quick-change interface, validated to 1,000,000 cycles.Automation, ME

Much of our work is under NDA. Contact us and we will walk you through relevant case studies on a call.

SHT 05

Shop capabilities

Processes, materials and tolerances.

Prototypes are produced in our own shop. Production parts come from an established supplier base in New England and Shenzhen that we have visited and qualified.

Manufacturing processes, materials, tolerances and lead times
ProcessMaterialsToleranceLead time
CNC machining6061 / 7075 Al, 303 / 316 SS, brass, Delrin, PEEK±0.025 mm5–10 days
SLA / SLS / MJFEngineering resins, PA12, TPU±0.15 mm2–4 days
Urethane castingPU, Shore 20A to 80D±0.25 mm1–2 wks
Sheet metalAluminum, mild steel, stainless±0.2 mm1–2 wks
Injection moldingABS, PC, PC/ABS, PA66, TPE, LSR±0.1 mm4–8 wks tooling
Die castingADC12, A380, Zamak 3±0.1 mm6–10 wks tooling
SHT 06

Studio

An integrated team that delivers the whole product.

We are industrial designers and mechanical engineers based in Massachusetts, USA, working with founders on their first device and with established companies on their next platform.

There is no hand-off between a design agency and an engineering firm. One team carries the product from brief to production, so nothing is lost between disciplines.

Discovery first
Every engagement begins with a fixed-scope, two-week discovery sprint. You receive a requirements document and a development plan that you are free to take anywhere.
One lead
The engineer who runs your kickoff is the one on the factory floor for first articles.
You own the files
Native CAD, drawings and supplier relationships are yours at every stage, not only at the end.
Weekly builds
Something physical on the table every week, from early foam models to production-intent prototypes.
SHT 07

Start a project

Tell us about your project.

A short description is enough. We respond within two working days with questions and, where there is a fit, a proposal for a discovery sprint.

Prefer email? hello@toolinc.com