The term engineering derives from the Latin ingeniare ‘to devise or contrive’. That origin perfectly encapsulates the mindset driving our work at Stage One. Every project we undertake begins with a problem that demands a technically robust, inventive, and precisely engineered solution.

In many cases, the optimal solution involves integrating a system from an array of existing components, some drawn from our in-house inventory, others procured off the shelf. However, it is often the third route, designing and manufacturing bespoke components, that delivers the highest value to our clients. This is where our engineering capability truly differentiates us, both in terms of design sophistication and speed of delivery.

From Concept to CAD

The design process typically originates within our engineering department, where designers and mechanical engineers translate conceptual sketches into manufacturable designs. A part may begin as a hand-drawn sketch but quickly transitions into a fully dimensioned model in Autodesk Inventor. These digital models not only define geometry but also embed tolerances, material data, and manufacturing intent laying the groundwork for precision fabrication.

Rapid Prototyping and Manufacture

Once models are validated, shop drawings are produced and these files are transmitted directly to our machine shop, where they can be produced almost immediately. Our facility is equipped with multi-axis CNC machining centres, precision lathes, and high-speed milling machines, enabling us to produce almost any type of engineered part from steel or aluminium.

Testing and Refinement

Parts combine to create assemblies. These assemblies are load tested, soak tested and often become part of a larger test build process. The functional performance of the parts then informs further design development as necessary. These iterations enhance reliability and reduce downstream risk before deployment to site.

Agility in Practice

One of the most rewarding aspects of this capability is its application in the field. It’s not uncommon for our team to receive a late-night call from a site thousands of miles away describing a critical on-site issue. Within hours, our engineers can model a new component, machine it in-house, and dispatch it via the next available flight. That ability to turn a potential showstop into a success story overnight is the very essence of engineering agility.

Creative Problem-Solving

Our strength lies in combining engineering ingenuity, operational flexibility, and advanced manufacturing technology. Together, these capabilities enable us to solve complex, time-sensitive challenges that others simply can’t fix. And this is something that sets us apart and of which we’re proud.

Explore some of the intricate assemblies and precision components developed by our engineering team and when your next project throws up a tricky problem, bring it to us. We’d love to show you how we engineer a solution.