Design with confidence
Get the engineering evidence you need before you commit to tooling, manufacture, or production.
FEA and engineering analysis to support product development decisions.
Find the problem while it is still cheaper to change
Tooling, manufacture, and full-scale testing turn design assumptions into expensive commitments.
Before you take that step, you may need to know:
Will the design withstand the loads it will face?
Where are the likely weak points?
Which assumptions matter most?
Should the design change before manufacture?
Instar helps manufacturers and product designers navigate engineering uncertainty.
What evidence is sufficient to make the next decision?
Start with the decision, not the software
Good engineering does not begin with the most complex model.
Sometimes first-principles calculations are enough.
Sometimes the geometry, materials or loading require finite element analysis.
Sometimes the real question is about vibration, contact, fatigue, standards or how a physical test should be approached.
The method should follow the decision.
FEA & structural analysis
Understand how a product or component is likely to behave under real loads.
Assess stress, strain, deflection, fatigue, vibration and other critical behaviours before the next major design commitment.
Design verification before manufacture
Understand how a product or component is likely to behave under real loads.
Assess stress, strain, deflection, fatigue, vibration and other critical behaviours before the next major design commitment.
Product development engineering
Turn practical knowledge, design intent and technical requirements into a clearer path toward a manufacturable product.
Support can include engineering calculations, CAD, design refinement, design for manufacture and preparation for testing.
Independent design reviews
Get a fresh technical view before the next important decision.
Identify key assumptions, unanswered questions and potential risks before committing more time and money.
A founder-led engineering consultancy
Instar is led by Dr Sam Evans, a mechanical engineer and founder with more than 10 years of experience across engineering, physical-product development and commercialisation.
Sam has contributed to engineering and product development work across more than a dozen physical products for Australian companies.
His experience includes finite element analysis, engineering calculations, CAD, design for manufacture, standards review, prototyping, tooling decisions and taking a hardware venture from university IP through manufacturing and first sales.
That commercial context shapes the way Instar approaches engineering.
Who I work with
Manufacturers approaching an expensive production phase
You have deep practical and manufacturing knowledge, but need specialist engineering evidence before tooling or production.
Technical and asset teams with a specialist capability gap
You understand the equipment or process better than anyone, but need analysis capability that does not exist in-house.
Technical founders facing the next investment decision
You have a concept or prototype and need independent engineering evidence before committing to the next iteration.
Independent design reviews
Get a fresh technical view before the next important decision.
Identify key assumptions, unanswered questions and potential risks before committing more time and money.
My experience spans manufacturers, product-focused companies, start-ups, and heavy industrial.
Manufacturing & industrial products
Renewable energy & clean technology
Plastics, polymers & moulded components
Recycling & circular economy
Construction, water & infrastructure
Heavy industry, equipment & rotating machinery
Get in touch to tell me about your project
It’s never too early for a quick inquiry
Let me know what you are working on, what barriers or uncertainties are you facing, or what feels unclear about upcoming product decisions.
I will review the information and let you know how I can best help.