NKY MECHANICAL DESIGNS, LLC
Independent Mechanical Engineering Consulting · Union, Kentucky
01ABOUT THE PRACTICE
NKY Mechanical Designs is an independent mechanical engineering consulting practice serving Cincinnati, Northern Kentucky, and clients across the United States. We help small and mid sized manufacturers, product companies, and inventors move complex ideas from concept to production with senior engineering firepower on demand.
Founded by Matthew E. Grubbs, a BSME with twenty eight years of hands on product design, tooling, qualification testing, and manufacturing engineering across defense, aerospace, automotive Tier 1, and consumer product companies. Named inventor on six granted and fifteen filed United States patents. Every engagement runs through the same person you meet on day one.
02SERVICES
> Product Design & Development
Concept through production. 3D CAD in Creo, SolidWorks, Solid Edge, Inventor, and CATIA. GD&T detailed drawings to ASME Y14.5. Design for manufacturing with domestic and international contract manufacturers.
> Tooling, Fixtures & SPM
Production tooling, jigs, gauges, and special purpose machinery. Access and clearance studies. 2D drawings and 3D models ready for fabrication and test. Full design evolution from concept through delivery.
> FEA & Simulation
Structural, modal, random vibration, shock, and thermal analysis in Creo Simulate and Inventor FEA. Load cases, boundary conditions, and acceptance criteria that stand up to design review.
> Qualification & DV Testing
Design verification and qualification per MIL-STD-810 thermal, vibration, and shock. Test plan authoring, execution support, and root cause failure analysis using 8D, 5 Whys, DFMEA, and PFMEA.
> Automation & Robotics
PLC programming on Allen Bradley and Mitsubishi platforms. Robotic cell design and integration with Fanuc, Motoman, and Panasonic. Vision systems, poka yoke fixturing, and Lean cell layout.
> Prototyping & Fabrication
Quick turn, low cost proof of concept prototypes in additive (FDM, SLA), CNC machining, sheet metal, and welded assemblies. Iterate fast to validate design intent before you commit to tooling.
> Patent & IP Support
Invention disclosure authoring, freedom to operate analysis, prior art review, and technical drawing support for provisional and utility filings. Six granted and fifteen filed patents of experience.
> Reverse Engineering
Legacy and obsolete parts brought back to life. 3D scan to CAD model to fabricated replacement. Ideal for line down emergencies and long tail spare parts that vendors no longer support.
03SELECTED EXPERIENCE
Senior New Product Design Engineer, promoted to Associate Manager, Mechanical Design. Hardened electromechanical fuze and safe and arm subsystems.
Senior Design Engineer. Consumer and retail product design, custom fixtures, LED lighting. Inventor on fifteen patent applications, six granted.
Senior Project and Manufacturing Engineer. Tier 1 automotive. Owned three million dollars in BMW and Honda tooling. Cut linear transfer line PPM from 1200 to 150.
Manufacturing Engineer. Launched the Toyota Corolla Lean Manufacturing exhaust line. Robotic welding, CNC bending, sheet metal forming, resistance welding, and CMM inspection.
04CAPABILITIES & TOOLING
- 3D CAD
- Creo (Pro/E), SolidWorks, Solid Edge, Autodesk Inventor, CATIA V5
- PLM / PDM
- PTC Windchill, ECN/ECO change control, BOM management, drawing release
- Simulation
- Creo Simulate, Autodesk Inventor FEA, DFMEA, PFMEA
- Standards
- ASME Y14.5, ASME Y14.100, MIL-STD-810, MIL-STD-331, JOTP-52, ITAR, EAR
- Tolerance
- 1D and 2D tolerance stack up, RSS, MRSS, Worst Case
- Automation
- Allen Bradley and Mitsubishi PLC / HMI, Fanuc, Motoman, Panasonic robotics
- Fabrication
- Additive (FDM, SLA), CNC, sheet metal, casting, injection molding, MIG, TIG, resistance and robotic welding
- Programming
- Python (CAD automation, scripting), C, Arduino
05CREDENTIALS
- B.S. Mechanical Engineering, University of Cincinnati, College of Engineering
- Six granted United States patents, fifteen filed applications
- Sole L3Harris presenter, NDIA Fuze Conference, 2021
- United States Citizen, experienced supporting ITAR and EAR export controlled programs
- Recipient, Faurecia "Best Launch 2007" recognition, BMW program, North America
- Twenty eight years of continuous mechanical design and manufacturing engineering
06INDUSTRIES SERVED
▸ DEFENSE & AEROSPACE ............... Fuze, S&A, munitions, hardened electronics ▸ CONSUMER & RETAIL PRODUCTS ........ Fixtures, merchandising, LED lighting ▸ AUTOMOTIVE ........................... Tier 1 tooling, welding cells, Lean lines ▸ INDUSTRIAL AUTOMATION ............... PLC, robotics, machine tending, SPM ▸ CONTRACT MANUFACTURERS .............. DFM support, drawings, qualification ▸ INDIVIDUAL INVENTORS ................ Patent support, prototyping, licensing
07ENGAGE
Most engagements start with a fifteen minute call to scope the problem. No cost, no obligation. If we are the right fit, we will put a simple statement of work together and get moving. If we are not, you will get a referral to someone who is.