Engineering Consultancy · Los Angeles · New York · Boston

The engineering team
your hardware startup
needed yesterday.

Stellar Forged embeds aerospace-trained engineers directly into your hardware programme. Engineering experience at SpaceX. Imperial College London. No overhead. Hardware that ships.

Currently accepting new clients Los Angeles · New York · Boston
Team experience · SpaceX · JLR · Imperial College London
Aerospace · Medical Devices · UAV & Drones · Robotics · Defense
US-based LA · NYC · Boston

Who We Are

Not a vendor.
Your engineering team.

Stellar Forged is team has engineering experience at SpaceX and JLR, and a background from Imperial College London, where tolerance stack-ups and CDR timelines are non-negotiable. We work embedded in your programme, not as a supplier at arm's length.

Your engineering lead is the person reviewing your drawings, flagging DFM issues before they reach the supplier, and telling you when a design decision will cost you time in production. Based across Los Angeles, New York, and Boston.

Imperial College London engineering background
Engineering experience at SpaceX and JLR
Retainer and fixed-scope engagements, starting within two weeks
CDR-standard deliverables on every project, every time

The Case for Us

Why Stellar Forged

Three questions every technical founder asks before hiring an engineering firm, and our honest answers.

Direct access to the engineer

You talk directly to the engineer doing the work. No account managers, no handoffs. The person on the call is the person at the CAD seat.

Aerospace-grade rigour

Every deliverable is CDR-standard, GD&T compliant, and supplier-ready. We build to the tolerances that matter, not the ones that are easy to hit.

Fractional, not freelance

Monthly retainer or fixed scope. We integrate into your tools: CAD vault, Notion, Slack. Scales with your programme. Onboarding takes days, not months.

What We Do

Core Engineering Services

Specialist expertise as a focused team, not a staffing agency.

01
CAD & Engineering Design

Parametric 3D modelling, GD&T drawing packages, tolerance analysis, and product design from concept through CDR. SolidWorks, CATIA, and Fusion 360.

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02
Manufacturing Engineering

Work orders, manufacturing drawings, BOM management, and supplier liaison. From first prototype through volume production, keeping programmes on schedule and on budget.

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Medical Device Engineering

We know what medical hardware founders need, and what the FDA expects.

Medical device development fails differently from consumer hardware. The risk isn't a bad product review. It's a 510(k) rejection, a design freeze slip, or a DHF that won't survive audit. Stellar Forged brings aerospace rigour to medtech programmes, with the regulatory literacy to match.

Early prototype design
Concept to functional prototype in weeks, structured for design iteration and eventual freeze.
DHF documentation support
Design History File structure, risk management file inputs (ISO 14971), and design controls.
Design for regulated manufacture
DFM for cleanroom and controlled environments. Biocompatible material selection to ISO 10993.
Design freeze packages
Complete drawing sets, BOMs, and specifications ready for 510(k) or PMA submission.
ISO 13485-aware process
Deliverables structured to support QMS requirements from day one, not retrofitted before submission.
Talk to a medical hardware engineer
device_design_rev_b.asm Active
// Classification
Regulatory Pathway510(k)
Device ClassClass II
BiocompatibilityISO 10993 ✓
// Design Status
Current RevisionRev B
DHF StatusIn Progress
Risk File (14971)Open
// Drawing Package
GD&T StandardASME Y14.5
MaterialTi-6Al-4V ELI
Cleanroom RatingISO Class 7
Design FreezeReady ✓
// Submission
Sterile PackagingSpecified ✓
BOM StatusReleased ✓
DHF PackageSubmitted ✓

Technical Depth

What We Bring to Your Project

Deep hands-on hardware and systems experience, covering the full product lifecycle from concept through production.

01
3D Modelling & FEA
Parametric modelling, stress and thermal simulation, structural analysis, and DFM reviews.
02
Drone & UAV Systems
Full-system design for unmanned platforms: payload mechanisms, frame structures, avionics integration.
03
Manufacturing Support
BOM management, supplier liaison, and production readiness to keep programmes on schedule.
04
Technical Documentation
CDR packages, ICD documents, and manufacturing-ready drawing sets that meet industry standards.
structural_assy_v3.asm Active
// Material & Mass
MaterialAl 7075-T6
Total Mass2.847 kg
Wall Thickness1.5 – 3.0 mm
// FEA Results
Von Mises (peak)312 MPa
Safety Factor3.2×
Max Deflection0.23 mm
FEA StatusPASS ✓
// Drawing Package
RevisionRev C
Tolerance± 0.05 mm
CDR ApprovalApproved ✓
// BOM Summary
Line Items47
Custom Parts12
Off-the-shelf35
BOM StatusReleased ✓

How We Work

Fast to start. Built to last.

Typical engagements start within two weeks. We integrate with your existing tools and workflow with no long onboarding or ramp-up overhead.

01
Brief

Tell us what you're building and where you're stuck. Initial calls require no commitment. Bring your CAD, your drawings, your problem statement.

02
Embed

We integrate into your tools: CAD vault, Jira, Notion, Slack. Up and running in days. You set the cadence; we work to it.

03
Deliver

CDR-standard deliverables from day one. Every file supplier-ready. Every drawing GD&T compliant. Every milestone hit.

Ready to move fast?
Let's talk about
your next project.

Retainer or fixed scope. Engagements start within two weeks. You'll talk to the engineer who will actually do the work.

Talk to an engineer See how we work