Engineering Services

Flexible Engineering Solutions for Tight Deadline Projects

Our engineering team has immediate access to expert data, machining, metrology, test resources, and the ability to rapidly iterate to decrease cycle times. This allows us the competitive ability to work with you on tight deadline projects while providing you with detailed data along the way.

Fallbrook Technologies Engineering Services (FTES) has a team of engineers who have a strong expertise around transmissions, vehicle driveline, controls, machining, and metrology. Our team of world-class experts specialize in mechanism design, actuation, controls, advanced analysis, test, prototype fabrication, vehicle simulation and system design, and product development processes. We are located in Cedar Park, Texas and support clients in the Austin area, Central Texas, as well as national and international clients.

Get to know us by the numbers:

  • 32 engineers including management with an engineering degree, 15 with advanced degrees
  • Over 640 years of cumulative engineering experience
  • Over 25 total technical papers published by engineering staff (both at FTI and previous companies)
  • Over 800 patents and patent applications worldwide covering inventions by our engineering staff
  • Recognized globally as experts in drivetrain transmissions

Industries We Serve: 

  • Automotive
  • Military and Defense
  • Biomedical
  • Aerospace
  • Consumer Product
  • Industrial Design

Our Core Expertise

Fallbrook has the engineering disciplines necessary to solve your problems from core R&D to production, systems engineering and implementation, and everything in between. Whether you need support with analysis and strategy, conceptual designs and showcasing prototypes, or commercialization and production, our passionate FTES team is ready to roll up their sleeves and help you craft the best engineering solution for your project.

ANALYSIS AND SIMULATION

Our engineering team will analyze and refine your design for geometry, weight, structure, function, thermal efficiency, vibration and safety. Our team demonstrates expertise in kinematic and dynamic system modeling, traction mechanics, tribology, rolling contact fatigue, advanced structural-thermal FEA, and computational fluid modeling. We use commercial computer aided engineering tools including ANSYS, ADAMS, Easy5, MATLAB and Simulink. We are proficient in programming languages including Python, C++, FORTRAN and VBA which we use to create and apply custom software tools.

PROTOTYPE FABRICATION

Our leading-edge machine shop specializes in high speed precision prototyping, low volume production and hard-milling (HRC 70). With more than 100 years of combined experience, our machine shop has a proven track record of producing high-quality, custom-designed precision machined parts on-time and within budget. We offer free consultation and 24-hour turnaround time on quotes to help you achieve your goals with the quality and responsiveness that you deserve. Learn more about FTES machining or view a list of our lab equipment and capabilities.

ASSEMBLY AND INTEGRATION

Our team draws experience from a diverse background in semiconductor, aerospace, electronics and automotive to provide assemblies and integration services for high precision, complex and robust electro-mechanical systems. Our flexible build areas allow us to manufacture, assemble, integrate and test your product. With close proximity and working relationship with engineering, machining, metrology, and test resources, we are able to meet tight deadlines without sacrificing quality.

PRODUCT DESIGN

Our product design team is constantly evolving research methodologies to better understand the goals of your project, how it will affect the end users, and to uncover hidden opportunities. Our mechanical product design expertise includes advanced mechanism design, component design, and assembly level design using PTC Creo design software. We also provide electrical product design services which includes PCB design, control system design, firmware and software development.

METROLOGY

Our metrology laboratory is built to be responsive to your needs and ready to handle any project, big or small. We specialize in first article inspections (FAIs) and tight tolerance applications. When it comes to supplier validation, our high-tech measurement equipment is up to the task. Our primary scanning CMM can achieve an accuracy of 1.6µm (<.0001in), our secondary CNC systems are accurate to 5µm (.0002in) or better, and our 3D Scanner and other equipment are accurate to 20µm (<.001in). Learn more about FTES metrology or view a list of our lab equipment and capabilities.

VALIDATION TESTING

We provide test planning, test process, test procedure, highly accelerated life test (HALT), DVP&R, and test stand development. Our comprehensive product testing includes function, performance, operating limits, fatigue, environmental and durability. Our state-of-the-art testing facility covers over 12,000 sq. ft. and includes specialized test stands tailored to our product development and design validation. This provides us with the capability to conduct advanced testing that can’t be done cost effectively by outside labs.

PROGRAM MANAGEMENT

Drawing experience from the automotive, defense, biomedical, aerospace, consumer product, and industrial design industry, our experienced program managers (PM) will work with you to ensure a successful initiation, planning, design, execution, monitoring, controlling and closure of your project.  In addition to handling component sourcing, production development, and supplier quality management, our PM will be your primary point of contact and will oversee the overall scope, schedule, budget, and success of your project from start to finish.

Average Project Cycle

Our integrated, cross-functional team routinely delivers on fast-paced projects. Below is a typical example of the average project cycle for the following Bill of Materials: 100-250 rows and approximately 30 highly custom and complex parts.

Fallbrook Product Development Average Project Cycle

Our Test Facility

We have the expertise and facility to design and build custom test stands specific to your application. Our team does this every day with our in-house design department, machine shop, and metrology lab.

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Test Stands

In the last 15 years, our team has designed, constructed, and validated over 50 test stands. Many of these are still in routine use, including:

  1. (1) reconfigurable 125hp double-ended AC dyno stand with DAq and instrumentation
  2. (2) reconfigurable 40hp double-ended AC dyno stand with DAq and instrumentation.
  3. (6) 20hp durability stands
  4. Many other highly customized test stands suited for assessing functional performance, operating limits, and durability of transmission assemblies or components.

Test Equipment

Below are some of the test equipments we have and typically spec in our test facility:

  1. National Instruments Labview and data acquisition hardware
  2. HBM T40B torque transducers
  3. ABB ACS880 variable frequency drives
  4. Various thermocouple, pressure transducers, position transducers, etc.