Portfolio
Expertise
Fluid Mechanics and Cooling Technology
Porticos was previously awarded a grant from Homeland Security for developing this Technology. Porticos is presently implementing this into a product called the Porticool Personal Cooling System. Please visit the Porticool Website at http://www.porticool.com/.
Miniature Fluid Systems
Porticos has years of experience in miniaturization of fluid systems. This custom manifold is smaller than a nickel, and is used to distribute liquid CO2 at pressures near 500 PSI and temperatures below -40 C.
This fuel-cell represents the other end of the spectrum. The fluid is both hot and corrosive, making material-selection critical. Connections must be very reliable, as a leak would damage the entire system.
Miniaturization of fluid components requires knowledge of the limitations of fabrication technology… and the expertise to push those limits. This combination-valve was designed to minimize the thermal mass of the device while permitting automated machining of the valve-body to facilitate economical, high-volume production.
Thermal Design
Harman-Becker developed a high-end audio amplifier for the sound system in new Chrysler vehicles, but it tended to run hot.
Porticos analyzed the temperature distribution within the unit, then recommended modifications to more effectively dissipate the heat.
Battery Technology
As experts in mechanical design for portable consumer electronics, we have built an expertise in packaging several of the industries leading battery technologies. Complexities that arise from the chemical makeup of today’s energy cells, such as Lithium Ion, Lithium Polymer, and Nickel Metal Hydride, require special attention with the mechanical design.
Fixtures and Mechanisms
One great way to distinguish your product is with how it is opened or activated. Covers and latches must work smoothly and reliably to demonstrate the feel of quality to the customer. These components can be designed to integrate with the product styling and can incorporate lockouts to prevent improper use.
Porticos is experienced in designing all manner of mechanisms and devices. Some examples include small mobile phone hinges and sliders, medical device lids and enclosures, high volume test fixtures, and even heavy industrial platforms.
Clients can utilize Porticos’ mechanical engineering skills and experience to design other functional mechanisms and fixtures to meet their individual needs.
EMI Shielding
As electrical devices become smaller and electrical components are squeezed closer together EMI (Electro-Magnetic Interference) shielding has become increasingly more complex. At Porticos we have experience with a broad list of shielding solutions.
Many of our customers only require a simple stamped or drawn shield can, perhaps a fence and lid style for easy testing. But many times the unique geometry requires a more flexible solution, such as a dispensed gasket or a metal-plated plastic shield.
At Porticos excellent customer service means that we will foster a creative solution as we work closely with your electrical engineers to achieve the most efficient layout of the components while giving you the shields required for the best performing final product. We have working relationships with various shield manufacturers, including BiLink, AK Stamping, and Thong Fook.
Paint
Surface finish makes a statement about your product, and can help build brand strength, as well as increase sales. At Porticos your objective is our objective and the vision you have for your final product will be our vision as well. We have a wide variety of experience painting plastic and metal parts.
This space-age phosphorescent pigment can be used in painting, screen-printing, or pad-printing. It glows brightly in the presence of ultraviolet light, and continues to glow for several minutes afterwards.
A major computer manufacturer asked Porticos to investigate fluorescence and phosphorescence as a means to illuminate controls. We constructed several working prototypes that were easily usable in total darkness, and scalable for high-volume manufacturing.
Die Casting
To achieve the proper strength of your mechanism many times a die casting is the best answer. At Porticos we specialize in deciding when a metal part is preferred over an injection molded plastic. As strong as engineering-grade plastics have become, sometimes a die casting is the better choice. We use FEA (Finite Element Analysis), engineering calculations, and our own product design experience to determine the proper material and manufacturing method for your application.
If a die casting is appropriate, these tools also help us select the proper aluminum or magnesium alloy to meet your product performance specifications. Our knowledge and experience with die cast tooling helps ensure that we design the part right the first time, and avoid the often costly or life-shortening changes to the tooling. We have working relationships with die casters such as Funfiek and Dynacast, but will also work well with the manufacturer of your choice.
Thixomolding and Powdered Metal
Because many of our customers are in the consumer electronics business, miniaturization is driving their product design to include high-strength, high-precision, and often cosmetic metal parts. These parts can have very fine detail, thin walls, and require tight tolerances or near net shapes. At Porticos we are experienced designing parts for high-speed injection molding of semi-solid magnesium alloys, a process known as Thixomolding.
We have worked closely with Thixomat to learn the unique design rules required for their patented manufacturing method. We have also worked with manufacturers such as Specialty Pressed Components, to design precision powder-metal pressed parts from brass, stainless steel, or other metal alloys.
Injection Molding
Any firm that claims an expertise in mechanical design of consumer products must be masters at designing parts for the plastic injection molding process. At Porticos our portfolio is full of injection molded parts made from virtually every engineering-grade plastic formulated (PC, ABS, Nylon, PBT, POM, etc.).
As the cornerstone of our mechanical engineering competency we will settle for nothing less than exceptional cosmetics, function, durability and precision of every injection molded part we design. We partner with both domestic and overseas injection molders who share our passion for the perfect part.
Insert Molding
If your part is multi-functional and would benefit from the reduced assembly cost of insert-molding than Porticos has the experience to bring your design to fruition. We have an eye for precision and the unique tooling experience to design insert-molded parts from a wide variety of materials (PC, ABS, Nylon, PBT, POM, etc.).
We have working relationships with both domestic and overseas molders and will be there to support them as they work out the exact press parameters required to create your insert molded part.
Overmolding
Over-molding, the process of molding one plastic or rubber material on top of another, has been used for many of our customers with superb results. Whether you desire a rugged look and feel, or are adding a grip for ergonomic reasons there are several unique design parameters that must be met to achieve a quality over-molded part. At Porticos we have a full understanding of these parameters and can engineer your unique geometry to meet your functional requirements.
We will utilize the properties of the materials to achieve the proper chemical adhesion, as well as add features for mechanical adhesion when required. We have the tool experience and working relationships with domestic and overseas molders. Porticos works with the molder and will be there to support them as they work out the exact press parameters required to create your over molded part.
In-Mold Decorating
In Mold Decoration evolved for high volume applications in order to create abstract designs and other artistic expressions on a curved plastic surface. The technique has been mastered by custom print shops such as Nissha IMD and has been used not only for decoration but also the application of various protective hard coatings. While each plastic piece is confined to typical mechanical design standards, there are also specialized design rules that must be applied to an in mold decorated part. These are due, in part, to the complexities in the tooling that must be in place to receive the decorated foil. At Porticos we have experience with these complexities and the knowledge to design an in mold decorated part that will give the precise cosmetic look your industrial designers were asking for.
Precision Presswork
Our engineering team is experienced is various forms and thicknesses of sheet metal bending, plating and welding. For smaller, more complex parts of constant thickness progressive die stamping has proven to be a dependable manufacturing method.
Often these complex parts serve an electrical purpose as well. The Porticos team is educated and experienced in selecting the proper metallurgy for the job.
For multi-functional parts, such as the antenna shown here, we have also employed selective plating which saved our customer money. These types of parts are ideal for both a complex product development effort and short production runs, as small batches can be easily made with a CNC laser.
Joining and Welding
During the mechanical design process just as much care and attention should be given to the way each part is assembled as there is to the design of each part itself. At Porticos we understand that it’s important to have more than one assembly tool in your tool belt.
Over the years we’ve built up our experience base in heat staking, ultrasonic welding, and the use of various glues and adhesives. We’ve also built relationships with many different equipment makers, such as Branson Ultrasonics. The design constraints of each unique product dictate which method is best for the job. We are prepared to bring the right tool to the manufacturing floor to ensure a successful assembly of your product.
Computer Aided Design
At Porticos our engineers are proficient in Unigraphics, Pro/Engineer, and SolidWorks.
We see our CAD software as just one of many tools used to achieve the highest quality overall mechanical design for our customers.
We have built our skills in various software packages so that we will be able to select the best tool for a given job. In this manner we are able to bring a level of flexibility to our customers that is uncommon in the mechanical design industry.
Finite Element Analysis
When engineering calculations do not give our engineers the assurance of quality and functionality that our customers expect in our designs we employ FEA (Finite Element Analysis) and other computational methods.
We utilize a variety of software, including Cosmos (Static, Vibration and Thermal), Ansys (Static and Thermal), and FloTherm (Thermal). Many of our customers come to us with a difficult engineering problem that can only be solved with these tools.
We have the experience to simulate real tests and predict true performance, which has resulted in successful problem resolution for our customers.
Custom Backlighting
The G2 logo on this panel is something special. Only the outline of the characters glow. The light propagates uniformly from the edges, parallel to the faceplate. The visual effect is remarkable.
Miniaturization
As products get smaller and their performance envelopes get extended, Porticos can utilize its experience in pushing the limit of existing manufacturing processes and in using other manufacturing processes to provide superior solutions.
Porticos engineers have been involved in a wide variety of miniature design applications, ranging from multi-functional connector solutions to hypodermic 2 phase fluid manifolds. We have the design and manufacturing knowledge required to solve the challenges associated with miniature components and products.
Vibration Solutions
Meeting vibration requirements can be a challenge for any electronic device, particularly for those units that need to be mounted within a land or air vehicle. Porticos has designed products to pass the rigorous MIL-810E test specifications.
Our engineers are experienced in performing vibration analysis and selecting or developing the appropriate isolation or dampening solution to meet your products needs. When needed we support our customers vibration testing and can design the proper test fixture to ensure that the vibration testing is not compromised by the custom mounting arrangement.