The Dimensional Forge — Sean Neal · Product Development On Demand

Services

Everything you need to get to the shelf.

Four practice areas, one engineer. I run only the Forge Method phases your project needs, and I tell you up front what it will cost.

// SYS_PLAN

Systems Architecture & Planning

I define the whole product before anyone builds a piece of it: requirements decomposition (PRD/FRD), risk analysis (FMEA), and technical roadmapping, so you know the budget before you buy tooling.

Systems ArchitecturePRD / FRD / SRD WritingDFMEA / SFMEATechnical RoadmappingBudgeting & Cost Modeling

// DESIGN_PROTO

Electromechanical Design & Prototyping

SolidWorks CAD, PCB integration, and rapid 3D-printed iterations. Your mechanics and electronics are designed together from day one, so they actually fit when manufactured.

Mechanical & Electromechanical DesignRapid Prototyping & DFM

// VV_DFM

Verification, Validation & DFM

Test plans and protocols that prove your product works. Once it’s validated, I prepare the engineering drawings and supplier quotes that make your design mass-manufacturable.

Verification & ValidationDFM / DFAEngineering DrawingsSupplier QuotingData Science & Analytics

// LEAD_MENTOR

Leadership & Mentoring

I lead cross-functional teams of teams, facilitate design reviews, and mentor engineers and students through hands-on technical coaching.

Teams of TeamsDesign Review FacilitationMentoring & CoachingEngineering Tutoring

Capped at $55 / hr with no-guess costing: every job is quoted before it starts, and there’s no retainer.

Start a Project Book a Discovery Call

Process

No retainers. No guesses.

Every project runs on the Forge Method: six phases from discovery to handoff. I scope only the phases your project needs and quote the hours and cost before work starts, so you never pay to figure out the plan.

Scope Your Project See the Full Method →

Phase 0 · Reading the OrderDiscovery & Definition

Phase 1 · Striking ConceptsConcept & Feasibility

Phase 2 · Shaping at the AnvilDesign & Verification

Phase 3 · Forging in MetalMaterial Prototype & Validation

Phase 4 · Tempering for ProductionProduction & Launch

Phase 5 · Banking the CoalsHandoff & Lifecycle

Past Work

Real quotes. Real products.

I quote the hours and the cost before work starts. These are proposals clients accepted, and work that got done. Each engagement runs only the Forge Method phases (0–5) the project actually needs.

Stealth Wallet — Design & Production

2025-06-30

$2,250Investment

150hHours

0–2·4Forge Phases

Full product development from concept through mass production readiness: sketching, CAD, photorealistic renders, proof-of-concept prototyping, DFM/DFA, supplier quoting, tooling, pilot run, and launch prep.

CAD Design 3D Rendering DFM/DFA Production Prep Supply Chain

Electromechanical Product — iOS Integration

2025-12-03

~$9.4KInvestment

235hHours

0–4Forge Phases

Full-cycle product development: multi-discipline architecture, 3D CAD, patent drawings, two prototype iterations (proof of concept, then a refined build with printed enclosure), iOS app MVP with hardware integration, and full production prep.

Systems Architecture Electromechanical Design iOS Integration DFM/DFA Prototyping

Tactical Light Prototype

2025-12-25

$1,518Investment

38hHours

0–2Forge Phases

Tactical/utility light from concept to shipped proof-of-concept prototype: requirements and ideation, full CAD development with mechanical and electrical architecture, physical build, testing, and delivery.

Mechanical Design Electrical Architecture Rapid Prototyping DFM/DFA

Medical Device Reverse Engineering

2026-09-26

$400Investment

8hHours

0·2·5Forge Phases

Teardown and reverse engineering of a client-supplied medical device: methodical disassembly with measured photo documentation, parametric SolidWorks models of the key parts, and a handoff package of native CAD, STEP files, and basic dimensioned drawings.

Reverse Engineering CAD Technical Documentation Engineering Drawings

Product Consultation

2025-07-11

$220 Investment

4h Hours

0 Forge Phase

Single live consulting session covering product goals, manufacturing approach, and a prioritized roadmap. Delivered a structured session plan, recorded call, and written summary with next steps.

Product Consulting Manufacturing Strategy Roadmapping

Automated Machine MVP

2026-05-20

$2,255 Investment

41h Hours

0 & 2 Forge Phases

Functional MVP based on a reference CAD design — actuated panels, sequenced motion, and button-based controls. Design review, CAD adaptation, full 3D printed build, and structured mechanism verification testing.

Mechanical Design Rapid Prototyping 3D Printing Electromechanical V&V

Mechanical Drawing Update

2026-03-01

~$240Investment

6hHours

0·2·5Forge Phases

Standardized title block and branding update across 40 mechanical drawings — logo swap, drawing number updates, and formatting changes delivered as a clean organized package.

Technical Documentation Engineering Drawings CAD

Battle Bot Engineering Tutoring

2026-04-19

~$700Investment

17.5hHours

4Sessions

Hands-on engineering tutoring for a 10-year-old: two parallel projects — build a new battle bot from a kit and diagnose/repair a broken one. Gus leads all hands-on work; I guide with questions only.

Engineering Tutoring Mentorship Hands-On STEM

Custom Pokéstop LED Sign

2026-04-27

~$230Investment

5.75hHours

0·3·5Forge Phases

Custom illuminated Pokéstop-style sign: acrylic sheet cut to silhouette, LED neon flex front face, spinnable pole mount, full QC testing with 8+ hour runtime validation.

Custom Fabrication LED Electronics Acrylic Work

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About

Led by Sean Neal.

Sean Neal, founder and lead engineer of The Dimensional Forge

I’m Sean Neal, a Senior Systems Engineer and product development consultant in Indianapolis. I analyzed rocket-engine test data at NASA Marshall Space Flight Center, interned twice at Tesla, did medical device R&D at SonaCare, and have spent eight years delivering connected hardware at Allegion, where I carried a WiFi smart-lock family from concept to retail shelves.

I started The Dimensional Forge so that experience could work for inventors, startups and small businesses who need senior engineering without a big firm’s overhead: from first concept through architecture, prototyping, validation and manufacturing readiness. When something goes wrong on a project I own it, say so plainly, and fix it.

Community
Authenticity
Courage
Integrity
Empathy
Vulnerability
Imagination
Hope
Pragmatism
Leadership

B.S. Mechanical EngineeringIUPUI + Ivy Tech, 2018Technical Certification in Design Technology · Ivy Tech Community College, 2014

3 patentsBlockchain access control (US 11,962,594 and US 12,609,936) and a passive standing-assist device (US2019/032088)

Cults3D Top Design2023 award

Upwork Top Rated100% Job Success

LinkedIn Profile ↗ Full Career & Portfolio →

Community & Leadership

Outside my day job I mentor, teach and organize. My leadership philosophy is simple: people first, systems second, ego last.

FIRST Robotics · Team 6956

Co-Lead Mentor · since 2019

I co-lead about 20 high school students through a six-week design, build and compete season every year, against a deadline that doesn’t move. I coach design, fabrication and project execution under pressure, and how to recover when something breaks.

Award · May 2021 FIRST Indiana District Chairman’s Team Award FIRST’s most prestigious award, for the team that best models its mission for other teams to follow.

Visit Sham-Rock-Botics ↗

Minority Engineering Program of Indianapolis

Co-Leader & Lecturer · since 2019

In 2019 I rebuilt MEPI’s 8th-grade engineering curriculum around Arduino, robotics and hands-on systems thinking, replacing an outdated program. I’ve designed and taught it every year since, to open a path into engineering for students who are underrepresented in it.

Allegion Pride Alliance

Founder · since 2022

I founded Allegion’s Indianapolis LGBTQIA+ employee resource group: I set its strategic agenda, recruited and lead a team of six volunteers, and serve as corporate liaison and Inclusion & Diversity Chair. We ran Allegion’s presence at Indy Pride 2024.

Supportive Husband

Behind the scenes

My wife, Eleanor Hernly, LMHC, is an incredible therapist in Indianapolis. I’m proud to help out behind the scenes with operations, support and spreading the word about Eleanor’s practice, which offers in-person and online sessions with a collaborative approach that blends mindfulness, ACT and DBT.

View Eleanor’s profile ↗

Forge Together

Start a project

Three ways in: send a project brief, book a discovery call, or call or text me directly. Every inquiry gets a reply from me, not an auto-responder.

Send a Project Brief

Your Name

Service Needed

Project Brief

Book a Discovery Call

30 or 60-minute call to talk through your project before committing to anything. Pick a time that works for you directly on my calendar.

What to expect

› Talk through your project and goals
› Identify the right service or engagement type
› No commitment required — just a conversation
› 30/60 minutes, video or phone

Schedule a Call

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Direct Line

No forms. No calendars. If you'd rather just reach out directly, call or shoot a text — I'll get back to you.

(765) 228-2824 Call or text · Indianapolis, IN

Pay me via

PayPal Venmo

For model purchases, commissions, and consulting invoices

From napkin sketch to manufactured product.