UNDERSTANDING TECHNICAL CHALLENGES.
DEVELOPING ENGINEERING SOLUTIONS.
DELIVERING PRODUCTS SUCCESSFULLY.
DIRK LANGE
DIPL. ING. (FH)
EXPERIENCE FROM ENGINEERING PROJECTS
More than 17 years of experience in product development, industrialization, product safety and automation.
Supporting engineering projects—from technical assessment and concept development through to successful implementation. Experience ranging from innovative SMEs to international industrial companies.
COLLABORATION
A CLEAR PROCESS. RELIABLE RESULTS.
1
ANALYSIS
CONCEPT
IMPLEMENTATION
HANDOVER
Understand requirements.
Define objectives.
Develop engineering solutions.
Evaluate technical feasibility.
Engineering Design.
Precise and Efficient.
Documentation and engineering data.
Ready for implementation.
2
3
4
Structured
Clear planning.
Focused execution.
Cost-Conscious
Keeping costs under control.
Maximizing value.
Practical
Experience gained from real engineering projects.
Production-Oriented
Designed for manufacturing.
Ready for the market.
Collaborative
Close communication.
Working together toward the best solution.
MY APPROACH
ENGINEERING WITH PURPOSE.
DELIVERING VALUE.
Engineering goes far beyond CAD models.
Successful engineering requires technical expertise, economic thinking and robust solutions that perform reliably throughout development, manufacturing and series production.
Preview of selected engineering projects in product development, product safety and automation.
Universal Clamping System for Tool Holders
Medical Technology Platform
Transforming industrial design into manufacturable products.
Creating modular product architectures.
Designing for manufacturing.
Risk Analysis & Product Safety
Developing safe products.
Managing technical risks.
Automation & Manufacturing Solutions
Integrating robotics.
Automating production processes.
Demonstrating technical feasibility.
Reducing wear.
Lowering costs.
Achieving production readiness.
SELECTED ENGINEERING PROJECTS
TECHNICAL PROJECT SUPPORT
Supporting the implementation, stabilization, and further development of mechanical and mechatronic products, assemblies, and technical systems.
Typical Applications:
• Development Projects Facing Delays
• Additional Engineering Capacity Required
• Solving Complex Technical Challenges
• Risk and Root Cause Analysis
• Industrialization Projects
Deliverables:
• Execution of Defined Work Packages
• Support for Technical Decision-Making
• Engineering Design and CAD Development
• Risk and Problem Analysis
• Accelerated Project Execution
Tailored to Project Scope and Duration
ENGINEERING CONCEPT DEVELOPMENT
From requirements to robust engineering solutions.
Typical Applications:
• Mechanical and Mechatronic Products
• Technical Assemblies and Systems
• New Product Development and Product Enhancement
• Engineering and Investment Decisions
Deliverables:
• Development of 3 to 5 Concept Variants
• Concept CAD Models for Technical Evaluation
• Design Comparison and Risk Assessment
• Recommendation of the Preferred Solution
• Clear Recommendation for the Next Development Phase
Project scope tailored to your requirements
Typical project scope starting from €14,900 (net)
THE RIGHT SUPPORT FOR YOUR PROJECT
INITIAL TECHNICAL ASSESSMENT
A structured evaluation of technical challenges to support well-founded engineering decisions.
Typical Applications:
• Feasibility Assessments
• Product Concepts
• Technical Challenges
• Concept Evaluations
Deliverables:
• Assessment of the Current Situation
• Technical Evaluation
• Risk Assessment
• Up to Three Solution Approaches
• Clear Recommendations for Action
Project scope starting from €5,500 (net)
LET'S DISCUSS YOUR ENGINEERING CHALLENGE
Are you planning a new product, looking for additional engineering capacity, or facing a technical challenge?
Let's discuss your project in a no-obligation conversation and explore how I can best support your engineering objectives.
COLLABORATION
Every project has its own technical and organizational requirements. I tailor my support accordingly—from initial technical assessments and development concepts to the integration into ongoing engineering projects.
Collaboration is primarily conducted remotely and structured through regular project reviews and clearly defined deliverables. On-site meetings are arranged whenever they add value, for example for technical evaluations, workshops, testing, or project coordination.
The objective is an efficient and focused execution of engineering tasks with clearly defined responsibilities and transparent, measurable results.
ENGINEERING DEVELOPMENT
PRACTICALLY APPLIED
Engineering projects often require additional capacity, specialized expertise, or support in solving complex technical challenges.
I support the development, optimization, and industrialization of mechanical and mechatronic products, assemblies, and technical systems—from concept development and engineering design to supporting ongoing development projects.
The focus is on technical excellence, economic feasibility, and solutions that prove themselves in development, manufacturing, and real-world applications.
KEY AREAS OF EXPERTISE
Every engineering project comes with its own technical, commercial, and organizational requirements.
The following examples provide insights into selected projects in product development, product safety, and automation, demonstrating how technical challenges were transformed into practical, production-ready solutions.
UNIVERSAL CLAMPING SYSTEM FOR TOOL PRESETTING MACHINES
An existing clamping system was required to accommodate a wide range of tool holders while maintaining high repeatability and measurement accuracy. In practical operation, however, limitations became evident in terms of wear resistance, operational reliability, and long-term durability.
The objective was to preserve the system's universal compatibility while significantly reducing critical loads and wear. At the same time, clamping force, functional reliability, and manufacturability had to be carefully balanced within the overall design.
I was responsible for the redesign and further development of the system through to production readiness. My work included analyzing load paths and wear mechanisms, optimizing the pneumatic actuation system, and developing and validating new design concepts through prototyping and testing. Design-for-manufacturing and assembly considerations, as well as preparation for series production, were integrated throughout the development process.
Optimizing component geometry, load distribution, and contact conditions significantly reduced critical stress concentrations and wear. The result was a robust, low-maintenance clamping system offering improved operational reliability, lower service requirements, and more efficient manufacturing and assembly processes.
MEDICAL DEVICE HOUSINGS FOR IMPLANTOLOGY AND SURGICAL SYSTEMS
An industrial design concept had already been developed for a new generation of implantology and surgical systems. The challenge was to transform this concept into a manufacturable, regulatory-compliant, and production-ready product while preserving its design intent. At the same time, existing platform components had to be retained and the architecture prepared for future product extensions.
The project required balancing the demands of industrial design, medical device engineering, injection molding, assembly, and series production within a single product concept. Beyond the technical implementation, manufacturability, modularity, and long-term scalability were key design objectives.
I was responsible for the enclosure development and for translating the industrial design into a production-ready injection-molded housing. My responsibilities included CAD design of the assemblies, design optimization for injection molding, coordination with toolmaking, and integration of existing production components. In addition, I developed a modular platform concept that enables future product variants and upgrades.
The result was a production-ready enclosure system for medical devices, featuring optimized manufacturability and assembly, seamless integration of existing platform components, and a modular architecture designed to support future product variants.
RISK ANALYSIS AND PRODUCT SAFETY IN PRODUCT DEVELOPMENT
Modern technical products must not only meet functional requirements but also comply with comprehensive safety and regulatory standards. Particularly in mechanical engineering and medical technology, potential risks must be identified and systematically assessed at an early stage of the development process.
The challenge is to integrate safety requirements into the development process from the outset, minimize technical risks, and deliver practical, economically viable solutions. Safety engineering must be embedded throughout product development, closely aligned with engineering design, technical requirements, and overall product performance.
Across multiple development projects, I was responsible for evaluating safety-related aspects from an engineering perspective. This included conducting risk analyses, assessing hazards and residual risks, defining risk mitigation measures, and supporting CE conformity processes. In addition, safety requirements were incorporated into the product design, while technical intellectual property and patent-related aspects were also evaluated.
By addressing safety and regulatory requirements early in the development process, technical risks were systematically reduced and engineering decisions were supported by a structured risk-based approach. The result was technically robust, well-documented product solutions that support regulatory compliance and provide a solid foundation for successful product development.
AUTOMATED TOOL PRESETTING AND HANDLING CELL WITH ROBOTICS INTEGRATION
An automated process cell was developed for a trade fair demonstration to combine several previously manual tool presetting operations into a fully integrated automated workflow. The objective was to demonstrate the technical feasibility of an automated tool handling process under realistic operating conditions.
The challenge was to seamlessly integrate multiple process steps—including tool handling, shrink fitting, cooling, and balancing—into a safe, precise, and reliable automated system. At the same time, robotics, safety requirements, positioning accuracy, and process stability had to be incorporated into a single machine concept.
I led the concept development, layout design, and mechanical implementation of the automation cell. My responsibilities included developing the overall process flow, designing the mechanical peripherals, developing a dedicated robotic gripper, and defining transfer and positioning concepts. In addition, I conducted risk analyses, evaluated machine safety concepts, and coordinated collaboration with software, hardware, and automation partners.
The result was a fully functional trade fair demonstrator featuring a continuous automated process chain. The successful integration of robotics, peripheral equipment, and machine safety concepts demonstrated the technical feasibility of automated tool presetting and established a solid foundation for future automation solutions.
The project examples presented are based on real engineering experience. Confidential information, as well as company and product references, has been anonymized.
