For inventors, startups, hobbyists, and small businesses that need experienced product development without a full-time hire.
Indianapolis, IN · Est. 2024 · Forging Dimensions: Utility, Fun, Artistry!
Sean Neal is a Senior Systems Engineer and product development consultant based in Indianapolis. Background spans NASA Marshall Space Flight Center, Tesla (two internships), SonaCare Medical, and 8 years delivering connected hardware products at Allegion.
The Dimensional Forge is a consulting practice for inventors, startups, and small businesses that need senior engineering leadership — end-to-end, from initial concept through architecture, prototyping, validation, and manufacturing readiness.
One engineer. Full lifecycle. No hand-holding required from your side.
For inventors, startups, hobbyists, and small businesses that need experienced product development without a full-time hire.
End-to-end product architecture from concept to production. Requirements decomposition, interface definitions, system-level design reviews.
SolidWorks CAD, GD&T, tolerance analysis, and electromechanical integration for multi-discipline products.
Fast iteration from idea to physical part, with design-for-manufacturability guidance built in from the start — not tacked on at the end.
Clear, structured technical documentation — product requirement docs, functional specs, and system requirement documents that teams can actually build from.
Systematic failure mode identification and risk mitigation before your product reaches a customer. Design and system-level FMEA execution.
V&V planning, test protocol development, and results analysis. Documented evidence your product meets its requirements.
From napkin sketch to phased roadmap — with realistic milestones and resource budgeting aligned to your actual constraints.
Bottom-up cost models, BOM costing, margin analysis. Know whether your product makes business sense before you commit to tooling.
Python and MATLAB-based analysis, ML applications, and data pipeline development for engineering and product decisions.
Starting at $55 / hr — no cost surprises, no retainer required.
Selected projects across aerospace, medical devices, automotive, IoT hardware, and product consulting.
End-to-end product ownership for a family of WiFi-enabled deadbolts and lever locks — concept through retail launch. Coordinated hardware, firmware, mobile app, and cloud teams using a teams-of-teams approach. Led DFMEA/SFMEA sessions, System Design Reviews for director-level stakeholders, and full V&V planning in Azure DevOps. Embedded structured root-cause methods (5-Whys, A3, 8D) directly into design review culture.
Analyzed large raw data sets from RS-25 rocket engine hot-fire tests to identify operational anomalies. Built a reusable MATLAB/Python data analysis tool with a full GUI — designed for long-term use by future Marshall engineers, not just the duration of the internship. The RS-25 is the main engine of the Space Launch System.
Led medical device components through the full early design cycle: concept, SolidWorks modeling, 3D-printed and cast urethane prototyping, fabrication, validation testing, and test report authorship. Set cable specifications and created 2D/3D electrical routing diagrams. Managed task breakdown and timelines for product realization.
Two internships across Fremont and Palo Alto. Designed and released 3D CAD models using GD&T best practices; coordinated development of cast and stamped aluminum structural parts for Model S and X. Separately: fastener selection and validation across cross-functional teams — Torque to Failure, Tensile, and Clamp Load testing with full root cause documentation.
Ongoing freelance consulting delivering end-to-end product development: requirement decomposition, DFMEA/SFMEA, V&V planning, prototyping, and manufacturing readiness. Top Rated status on Upwork with 100% Job Success Score. Top Design Award from Cults3D (2023). Custom-engineered products sold via Etsy. Rising Talent — Upwork (2025).
Real quotes. Real deliverables. Every card below is a proposal a client accepted and work that got done. Each engagement runs only the Forge Method phases (0–5) the project actually needs.
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.
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.
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.
Standardized title block and branding update across 40 mechanical drawings — logo swap, drawing number updates, and formatting changes delivered as a clean organized package.
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; Sean guides with questions only.
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.
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.
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.
Worked with The Dimensional Forge? I'd love to hear from you.
Leave a Review Here ↗Free open-source designs on MakerWorld. Paid premium models and award-winning prints on Cults3D. All designed and tested in-house.
Bambu Lab's model platform. Optimized print profiles, community downloads, and the full free Dimensional Forge catalog. Every design here is open — download and print at no cost.
Full model catalog on Cults3D — the world's largest independent 3D printing marketplace. Home of the 2023 Top Design Award win. Paid models, free releases, and the complete back catalog.
Need something custom? If you don't see what you're looking for, I take custom model commissions — functional parts, enclosures, fixtures, artistic pieces. Designed in SolidWorks, printed and tested before delivery.
Commission a ModelEngineering isn't just about building products. It's about building people.
Mentoring high school students through the full engineering cycle — challenge reveal to competition day. Teaching not just technical skills, but how to collaborate under pressure and recover from failure.
Co-revamped the 8th-grade curriculum in 2019 to include Arduino programming, robotics, and real mechanical engineering challenges. Building pathways for underrepresented students into engineering careers.
Founded and leads Allegion's LGBTQIA+ employee resource group. Led the company's Indy Pride 2024 presence. Manages a team of 6 volunteers driving visibility and belonging inside a global enterprise.
Three ways in — send a project brief, book a discovery call, or just call/text directly.
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.
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No forms. No calendars. If you'd rather just reach out directly, call or shoot a text — I'll get back to you.