# Deaton Engineering Mechanical and electrical engineering for design & build of complex machines and medical devices. Free no obligation consultations. Free estimates! Located in Georgetown Texas, near Austin. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png) ![Dell](https://deatonengineering.com/images/home-feature-tmgcore.jpg) ##### No Substitute for Being First Deaton and TMGCore create the first enterprise-grade, two-phase liquid immersion cooling platform for high-density, high-efficiency computing. [Case Study](https://www.deatonengineering.com/case_studies/tmgcore.php) ![Dell](https://deatonengineering.com/images/home-feature-battleready.jpg) ##### Battle Ready Deaton Creates a Military Hardened Design for Dell and U.S. Air Force. [Case Study](https://www.deatonengineering.com/case_studies/tbmcs.php) ![iFLY](https://deatonengineering.com/images/home-feature-ifly.jpg) ##### Design + Build Without Limits Deaton Manages a Mega Design and Build for iFLY [Case Study](https://www.deatonengineering.com/case_studies/ifly.php) ![Honda](https://deatonengineering.com/images/home-honda.jpg) ##### Critical Streamline Deaton Drives Efficiency for Honda Facility [Case Study](https://www.deatonengineering.com/case_studies/honda.php) [Previous](https://deatonengineering.com/#homeCarousel) [Next](https://deatonengineering.com/#homeCarousel) ## You Have a Vision. And now you have a partner to help you realize it. Welcome to Deaton Engineering. We're a full-service engineering company offering a wide variety of solutions and services to a broad range of industries. We provide talented specialists with applied experience and an excellent command of the tools of the trade. Above all, we partner with you to engineer answers. Deaton Engineering will help you improve an existing system - or create something new. [Call on us](https://www.deatonengineering.com/contact.php) to expand or supplement your team. And count on us to tailor engineering solutions that best meet your objectives. [One-Page Overview](https://www.deatonengineering.com//pdfs/deaton-engineering.pdf "Download a Quick Data Sheet") FEATURED CASE STUDY ## Building The World’s Largest Wind Tunnel in Dubai How do you build something that hasn't been done before? You source some of the best engineers and minds in the industry who are proven leaders within the sector. Pair that with Deaton Engineering’s 30 years of expertise then, introduce another industry leader in MLC CAD Systems with 40 years of experience. You’ve got yourself a dynamic duo equipped to solve whatever engineering problems may arise in striving for new heights. [Full Story >](https://www.deatonengineering.com/case_studies/ifly.php) ![](https://www.deatonengineering.com/images/logo-solidworks.svg) ![](https://www.deatonengineering.com/images/logo-mlc.png) ![](https://www.deatonengineering.com/images/logo-ifly.svg) ## Services Deaton Engineering specializes in the following engineering services: - [Finite Element Analysis](https://www.deatonengineering.com/services/elementanalysis.php) - [Complex Machine Design](https://www.deatonengineering.com/services/complex-machine-design.php) - [Software Engineering](https://www.deatonengineering.com/services/softwareengineering.php) - [Product Development](https://www.deatonengineering.com/services/productdevelopment.php) - [Process & Facilities Engineering](https://www.deatonengineering.com/services/facilitiesprocess.php) - [Automation Engineering & Robotics](https://www.deatonengineering.com/services/automation.php) - [Test Engineering & QA/QC](https://www.deatonengineering.com/services/customtest.php) - [Validation Engineering](https://www.deatonengineering.com/services/validation.php) - [Mechanical & Electrical Engineering](https://www.deatonengineering.com/services/machineequipment.php) - [Contract Manufacturing Services](https://www.deatonengineering.com/services/lowvolumemanufacturing.php) ## Industries We have worked with industries that demand both high-precision and scalable efficiency, including, but not limited to: - [Pharmaceutical Engineering](https://www.deatonengineering.com/industries/pharmaceutical.php) - [Food, Beverage & Dairy](https://www.deatonengineering.com/industries/foodbeverage.php) - [Medical Device Design](https://www.deatonengineering.com/industries/medicaldevices.php) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Egineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://deatonengineering.com/#carouselExampleIndicators) [Next](https://deatonengineering.com/#carouselExampleIndicators) #### FAQs: What services does Deaton Engineering provide in Texas? Deaton Engineering, based in Georgetown, Texas, offers specialized engineering services tailored to industries across the state, including: - Automation & Robotics – Custom automation solutions for Texas manufacturers. - Medical Device & Pharmaceutical Engineering – Supporting the Austin and Houston biotech hubs. - Food & Beverage Process Engineering – Enhancing production efficiency for Texas-based food processing plants. - Product Development & Prototyping – Helping Texas startups and manufacturers bring new ideas to market. - Test Engineering & Quality Assurance – Ensuring compliance with industry regulations, including FDA and USDA standards. Which Texas industries does Deaton Engineering serve? Deaton Engineering works with major industries throughout Texas, including: - Pharmaceutical & Biotech – Serving Houston’s medical research centers and Austin’s growing life sciences industry. - Food, Beverage & Dairy – Assisting San Antonio, Dallas, and Central Texas food processors with automation and process control. - Medical Device Manufacturing – Providing engineering and regulatory support for Texas-based device manufacturers. - Oil & Gas Engineering – Developing automation and testing solutions for Houston and Midland energy companies. Where is Deaton Engineering located? Deaton Engineering is headquartered at: 2 Sierra Way St, Georgetown, TX 78626 – Just north of Austin, allowing convenient access to Texas businesses statewide. How does Deaton Engineering support Texas businesses? Deaton Engineering partners with Texas-based manufacturers, research institutions, and industrial facilities to provide innovative engineering solutions. They work with companies across the Texas Triangle (Dallas, Houston, Austin, and San Antonio) to streamline production, improve automation, and ensure regulatory compliance. Does Deaton Engineering comply with Texas and national industry regulations? Yes! Deaton Engineering ensures compliance with Texas Department of State Health Services (DSHS) regulations, FDA, USDA, and ISO 13485 standards for medical device and pharmaceutical industries. They also follow Good Manufacturing Practices (GMP) and Good Automated Manufacturing Practices (GAMP). Does Deaton Engineering offer on-site support for Texas companies? Yes! As a Texas-based firm, Deaton Engineering provides on-site support and consultation for businesses throughout the state. Their proximity to major industrial hubs like Houston, Dallas-Fort Worth, Austin, and San Antonio allows them to offer hands-on assistance with testing, automation, and system validation. How does Deaton Engineering help Texas startups and manufacturers? Texas has a booming manufacturing and tech startup ecosystem, and Deaton Engineering supports local businesses by offering: - Prototype Development & Rapid Testing - Automation & Smart Manufacturing Solutions - Regulatory & Compliance Engineering - Scalable Engineering for Growing Companies ! # File not found (404 error) If you think what you're looking for should be here, please contact the site owner. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) Validation Engineering & FDA Compliance # Validation. Compliance. Confidence. ## Why Validation Matters — and Why Deaton Engineering is Your Ideal Partner [Validation Services Brochure](https://www.deatonengineering.com/pdfs/deaton-engeineering-services-validation.pdf "Download Data Sheet") A robust validation program not only ensures regulatory compliance—it sets your organization apart in a competitive market. Effective validation confirms that systems perform as intended, guarantees that products meet the highest standards of quality and safety, and significantly reduces the risk of FDA 483 observations. At Deaton Engineering, we specialize in helping clients succeed across the full spectrum of validation challenges—whether you’re launching a new process, upgrading legacy equipment, or preparing for an audit. We leverage a risk-based, **[Total Quality Approach](https://www.deatonengineering.com/services/validation.php#)** rooted in current Good Manufacturing Practices (cGMP), which allows us to deliver results even in the most complex environments. Deaton is committed to engineering-driven solutions. Our validation projects are executed by experienced engineers—not technical writers—who deeply understand your systems and processes. We take the time to assess every interrelated system to develop documentation that stands up to regulatory scrutiny and supports long-term compliance. Validation is not just a checkbox—it’s a continuous improvement tool. From process equipment and control systems to full facility validations, our team is equipped to prevent compliance issues or help remediate them when they occur. With Deaton, you gain a partner committed to quality, compliance, and operational excellence. ![Validation engineering: validation master plan, GMP criticality review, requirements analysis, user requirements, risk assessment, functional specification, vendor qualification, design specification, SOP, IQ, OQ, and PQ.](https://www.deatonengineering.com/images/diag-validation.svg) ## A Risk-Based Approach to Validation Services ### Regulatory Inspection & Audit Readiness - Inspection readiness assessments - Support for FDA/EMA audits - 483/CAPA response support and remediation execution ### Validation Master Planning (VMP) - Development of compliant, risk-based Validation Master Plans - Defines scope, systems impact, scheduling, roles, and responsibilities - Regulatory strategy built for successful inspections ### Commissioning & Qualification (FUSE CQV) - Full lifecycle qualification: DQ, IQ, OQ, PQ - Utility qualification: Clean Steam, WFI, HVAC, Compressed Air, etc. - Equipment qualification: Autoclaves, Bioreactors, Cleanrooms, etc. - Installation and start-up support ### Automated Process Control Systems (APCS) - Control systems and Building Management Systems (BMS) - SCADA, PLCs, and DCS qualification - Verification of alarm management, audit trail, user access, and data integrity ### Protocol Development & Execution - Development of IQ, OQ, PQ, FAT, SAT, and custom protocols - Execution of validation activities with clear, audit-ready documentation - Deviation management and change control coordination ### SOPs & Quality Document Support - Creation, revision, and harmonization of SOPs - Development of validation templates and standardized documentation - Onboarding and training of QA/QC and operational personnel ### Risk-Based Assessments & Gap Analysis - System impact assessments - GMP criticality ranking - Remediation strategies for legacy or undocumented systems - Data integrity assessments ### Computer System Validation (CSV) - Validation of GxP-relevant software applications - Aligns with GAMP 5 guidelines and 21 CFR Part 11 - Services Include: - User Requirements Specification (URS) - Risk assessments and traceability matrices - Test planning and execution (IQ/OQ) - Audit trail and electronic signature verification - Validation reporting and change control support - Systems: LIMS, QMS, ERP, MES, Document Management Systems, e-Logbooks, and cloud/SaaS platforms ## Working With Deaton Engineering At Deaton Engineering, we are committed to helping you leverage modern technologies to bring innovative products to market faster, with greater efficiency and a stronger return on investment. Our custom-engineered solutions are designed for seamless installation, intuitive operation, and low-maintenance performance—all with minimal engineering support required. By reducing training needs, operator intervention, downtime, and revalidation efforts, we help lower your total cost of ownership while maximizing system uptime and reliability. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/validation.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/validation.php#carouselExampleIndicators) #### FAQs: What does CQV stand for, and why is it important? **CQV** stands for **Commissioning, Qualification, and Validation**. It’s a structured, regulatory-driven process that ensures facilities, utilities, systems, and equipment are properly designed, installed, and operating according to their intended use. It’s a critical step for ensuring compliance with FDA, EMA, and global GxP regulations. What industries does Deaton Engineering support? We support **FDA-regulated industries**, including: - Pharmaceuticals - Biopharmaceuticals - Medical Devices - Contract Development and Manufacturing Organizations (CDMOs/CMOs) - Research laboratories and startups working with regulated products How is Deaton Engineering different from other validation providers? We bring a **hands-on, engineer-led approach** to every CQV and CSV project. Our team delivers: - Audit-ready documentation - Risk-based strategies aligned with **GAMP 5 and ICH Q9** - Practical field experience and regulatory insight - Custom validation plans tailored to your systems—not a one-size-fits-all template Do you offer Computer System Validation (CSV) services? Yes. We specialize in CSV for: - SaaS/cloud-based platforms - Quality Management Systems (QMS) - Laboratory Information Management Systems (LIMS) - MES, ERP, Document Control, and more Our CSV services align with **21 CFR Part 11, Annex 11**, and **GAMP 5** standards. Can Deaton Engineering help us prepare for an FDA or EMA inspection? Absolutely. We offer: - Gap assessments - Data integrity audits - SOP and documentation reviews - Remediation of 483 or audit findings - Staff training to ensure inspection readiness What types of validation protocols do you develop and execute? We provide complete lifecycle validation protocols, including: - Design Qualification (DQ) - Installation Qualification (IQ) - Operational Qualification (OQ) - Performance Qualification (PQ) - Factory & Site Acceptance Testing (FAT/SAT) All protocols are fully traceable and compliant with regulatory expectations. Do you support both greenfield projects and legacy system validations? Yes. Whether you’re starting a new facility or upgrading legacy systems, we tailor our CQV approach to your needs—minimizing downtime and maximizing compliance. Can Deaton Engineering provide onsite and remote validation services? Yes. We offer **hybrid service models** that combine onsite execution with remote documentation development, reviews, and digital collaboration, ensuring flexibility and efficiency. What’s included in your Validation Master Plan (VMP)? Our VMPs include: - Scope and system inventory - Validation strategy and risk rationale - Roles and responsibilities - Project schedule and milestone planning - Acceptance criteria and change control mechanisms How do I get started with Deaton Engineering? Start by contacting us for a consultation. We’ll evaluate your needs and propose a tailored validation plan. - Email: [sales@deatonengineering.com](mailto:sales@deatonengineering.com) - Website: [https://www.deatonengineering.com/](https://www.deatonengineering.com/) Why is validation engineering crucial for Texas industries? Start by contacting us for a consultation. We’ll evaluate your needs and propose a tailored validation plan. - Regulatory Compliance: Meeting federal and Texas state regulations, especially in industries like pharmaceuticals and medical devices. - Product Quality: Ensuring products are safe, effective, and meet quality standards. - Risk Mitigation: Identifying and addressing potential issues before they impact production. What areas can Deaton’s validation team help my company with? - GMP, cGMP, GLP, GAMP - System validation - Equipment validation - Process validation - 483 warning letters - Good manufacturing practices - Good laboratory practices - FDA compliance - Standard operating procedures (SOP) - User requirements specifications (URS) - Functional requirements specifications (FRS) - Software requirements specifications (SRS) - Validation gap analysis - Validation master plan - Installation qualifications (IQ) - Operational qualifications (OQ) - Performance qualifications (PQ) - Risk assessments - Hazard analysis - Deviation resolutions - Traceability matrices - Calibration management - Factory acceptance tests (FAT) - Site acceptance tests (SAT) - Network qualification - 21 CFR Part 11 - Process control system gap analysis & validation What systems and equipment can Deaton help my company validate/qualify? - Automated process control systems - Batch autoclaves - Boilers - Bulk material storage and silos - Cap assembly machines - Chillers and cooling towers - Clean in place (CIP) systems - Compressed air systems - Clean rooms - Clean steam generators - Coating systems - Continuous and batch sterilizers - Conveyor systems - Cryogenic equipment - Cutting systems - Dual chamber IV bag fabricators - Environmental enclosures - Extruders - Food grade printing systems - Form, fill, seal systems - HEPA filtration systems - HVAC control systems - Industrial inspection systems - Industrial robots - Measurement systems - Metal detection systems - Microwave pasteurizers - Miniature parts and mechanisms - Motor generator sets - Packaging & labeling equipment - Pick and Place machines - PLC and DCS control systems - PLCs, HMIs and computer controls - Pressure/vacuum vessels - Process hot water systems - Process piping systems - Process reactors - Process skids - Product handling equipment - Purified water and WFI systems - Rack mount equipment - Refrigerated storage - Robotic handling machines - Rotating equipment - Sanitary equipment - Scales and check-weighers - Shrink wrappers - Solution preparation systems - Stability incubators - Steam systems - Sterilize in place (SIP) systems - Thermal oxidizers - Total organic carbon (TOC) analyzers - Tote bin blenders - Vacuum chamber design and analysis - Vacuum conveyors - Vacuum environments - Vessels and tanks - Vision systems - Wave solder fixtures - Weldments and enclosures How can Texas companies collaborate with Deaton Engineering for validation services? Companies can contact [Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visit their Georgetown, Texas headquarters, a suburb of Austin, for consultations. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. # Pharmaceutical Engineering ## Deaton Engineering Understands Good Manufacturing Practices (GMP) The impact of long product development cycles, global competition, and current Good Manufacturing Practices presents a unique challenge to the pharmaceutical industry. When designing or changing a process, great care must be taken to balance international regulatory requirements with efficiency and cost. Managing these requirements makes pharmaceutical engineering a discipline unto itself. Whether you are scaling up a new process or modifying an existing one, Deaton Engineering can help. Our risk-based approach to pharmaceutical engineering is a proven strategy for managing process design, development, and change. Deaton Engineering partners with you to determine the best solution to meet your goals. Our engineering teams are highly skilled and experienced with the latest technologies. We deliver innovative equipment and system solutions using nonproprietary technologies (including open standards whenever possible) to accelerate adoption and simplify validation. Deaton Engineering understands current GMP requirements and follows the proven Total Quality Approach to providing engineered solutions. This approach can deliver substantial improvements in productivity while maintaining the highest assurance of product and human safety. ## Process & Facilities Optimization, Equipment ## Automation, and Regulatory Compliance **Machine Design & Process Automation** Deaton Engineering can design and build an individual piece of equipment or a complete manufacturing line to automate and improve your process. We use GAMP-compliant designs to create turnkey solutions that are reliable, cost-effective, and suitable for GMP validation. Deaton Engineering can also help identify, integrate, and validate your Process Analysis Technology (PAT) solutions. **Process Engineering, Facilities, and Safety** Deaton Engineering provides support services for production and utility systems in FDA-approved facilities. Our engineers can design, improve, or support the systems that run your operation -- including on-site construction management and start-up -- to help you every step of the way. **Risk-Based Validation Engineering and FDA Compliance** Our engineers provide turnkey validation services that cover the entire validation process. We can develop and execute qualification protocols for equipment, facility systems, and processes. Our documentation packages are extremely thorough and comply with regulatory requirements. Deaton Engineering can perform validations of automated control systems in accordance with 21 CFR Part 11. ## Pharmaceutical Engineering Services Process analysis technology (PAT) Performance qualifications (PQ) FDA, GMP, cGMP compliance & design 21 CFR Part 11 Current good manufacturing practice (cGMP) (GMP) Process development & optimization Good automated manufacturing practice (GAMP) Clean and sanitary design practices Quality assurance & quality control System design specifications USP purified water, water for injection (WFI) Measurement system analysis Design of experiments Statistical process control Pharmaceutical consultants Automated process control systems (APCS) Aseptic process & equipment design On-site construction management Quality by design and start-up support Bioprocess engineering System commissioning Standard operating procedures (SOP) Process and manufacturing equipment list User requirements specifications (URS) Process engineering services list Functional requirements specifications (FRS) Facilities engineering services list Software requirements specifications (SRS) Validation engineering services list Installation qualifications (IQ) FDA, regulatory and safety services list Operational qualifications (OQ) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) [![](https://www.deatonengineering.com/images/icn_pdf.gif)](https://www.deatonengineering.com/pdfs/industries/lowvolumemanufacturing.pdf "Download PDF") # Contract Manufacturing Services (CMS) & Engineering ## An Alternative to Offshore Contract Manufacturing Offshore manufacturing is often necessary for mature products to control costs and remain competitive. However, taking this step too early can severely hinder your efforts to get your best product to market quickly. An engineering and low-volume manufacturing partner can save you time and money by helping you develop and manufacture your product until its ready to be transitioned to overseas production. This is certainly the case in early stages of product development where volumes are uneven, engineering is incomplete, and assembly documentation is nonexistent. Deaton Engineering can help you keep pace with engineering changes on the fly while meeting your low-volume manufacturing needs. Your product will be managed by experienced engineers and built by skilled in-house technicians through this volatile transition period. Once the product has matured, Deaton Engineering can produce assembly instructions, drawings, procedures, and manufacturing bid packages to ease the transition to lower-cost manufacturing. ## Turnkey Design Services & Lean Manufacturing ### Product Development & Design - Alpha & Beta Phases Deaton Engineering can design the next-generation product as we build to meet current demand. Our designs reduce [manufacturing and tooling costs](https://www.deatonengineering.com/services/machineequipment.php) and ease the transition to contract manufacturing. ### Build to Order Assembly & Lean Manufacturing Deaton Engineering can [design](https://www.deatonengineering.com/services/productdevelopment.php) your product, fulfill orders, and ship direct to your customers as required to meet demand. Your product will be built by skilled technicians who are adept at managing production changes. Quality is guaranteed. ### Vendor Sourcing and Transition to High-Volume Manufacturing Not only do we produce documentation necessary for the transition to high volume manufacturing, but we also help you identify the right manufacturing partner. We have contacts with a number of domestic and international firms to help get you started. ## Engineering, Manufacturing, & Design Services - Custom part development - Lean manufacturing - Box build - Manufacturing engineering - Product manufacturing & assembly - Electronic manufacturing & assembly - Machine manufacturing & assembly - Insourcing & inshoring - Flexible manufacturing - Computer aided manufacturing (CAM) - Mechanical & electrical assembly - Manufacturing on demand - Enclosure assembly - Startup manufacturing - Low volume manufacturing - Cable and harness assembly - Electromechanical assembly - Contract manufacturing organization (CMO) - Contract manufacturing services (CMS) - Rapid prototypes & first articles - Program management - Timeline and budget development - Testing support: shock, vibration, & packaging - Assembly instructions - Purchased part specification - Detailed bill of materials (BOM) - Vendor management - Manufacturing bid packages - Prototype development & verification - Design for manufacture - [Test engineering and quality assurance](https://www.deatonengineering.com/services/customtest.php) - [Engineering services list](https://www.deatonengineering.com/services/lowvolumemanufacturing.php#) - [Manufacturing services list](https://www.deatonengineering.com/services/lowvolumemanufacturing.php#) - [Product development experience list](https://www.deatonengineering.com/services/lowvolumemanufacturing.php#) #### FAQs: What low-volume manufacturing services does Deaton Engineering provide in Texas? Deaton Engineering offers: - Prototype Development: Building initial product versions for testing and validation. - Short-Run Production: Manufacturing limited quantities to meet specific demands. - Assembly Services: Providing mechanical and electrical assembly for low-volume products. How does low-volume manufacturing benefit Texas startups and small businesses? Low-volume manufacturing allows Texas startups and small businesses to: - Test Market Viability: Produce limited quantities to gauge market response. - Manage Costs: Reduce financial risk by avoiding large-scale production commitments. - Accelerate Time-to-Market: Quickly bring products to market without extensive lead times. Can Deaton Engineering assist with scaling from low-volume to high-volume manufacturing in Texas? Yes, Deaton Engineering helps clients transition from low-volume to high-volume manufacturing by producing necessary documentation, identifying suitable manufacturing partners, and ensuring a smooth handover.  Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How can Texas businesses start a low-volume manufacturing project with Deaton Engineering? Businesses can initiate projects by [contacting Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visiting their Georgetown, Texas headquarters, a suburb of Austin, for consultations. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. # What Your Dreams of Flying Really Mean It’s clear. Those dreams mean you need to visit the nearest iFly to simulate your own high-adventure #### skydiving. No experience necessary. ### The Client: iFLY, LLC iFly produces modern skydiving wind tunnels (both standard and custom) designed for the general public. You enjoy the completely immersive experience of skydiving without ever having to pack a parachute, pull a ripcord, or jump out of a perfectly good airplane. ## The Challenges Were Many: We Earned Our Wings Deaton helped take projects from the raw brainstorming and whiteboard stage… to collaborating with fabricators and suppliers for design of manufacturable and cost-effective components…across nearly all 9 generations of iFly Tunnel Systems. Here are just some of the challenges we researched and helped iFly and its suppliers overcome¬ Â Airflow sealing methods and solutions° Â Integrated sound dampening and conditioning (chilled turning vanes provide “air conditioning”)° Â Assembly, lifting, and installation challenges° Â Sealed joints within and sealed flexible joints between critical components. ## The Solution: Ideas Taking Flight For 20 Years We at Deaton have had the pleasure of working with iFly for 20 years. We ’ ve been involved and relevant at every phase, whether working on their standard designs or providing services for many of their custom projects, including the world ’ s largest wind tunnel and recirculating tunnels on cruise ships° Â The Concept “What If?” Phase: Whiteboard sketches and brainstormed conceptual designs were circulated among a diverse team of fabricators, control system and structural engineers, architects, aerodynamicists and owner groups to conceptuali ze machines° Â Ideas Meeting Real-World Constraints: We worked with fabricators using best practices to design manufacturable and cost-effective components to match complex geometry of desired airflow, and modular design for loading into shipping containers for transport around the world. * * * Getting Real and Realer: Used hand calculations, finite element analysis (FEA), and engineering judgement to optimize and validate designs. Developed methods to predict and evaluate component strengths, quantify internal/external loads and component responses. Created loading and interface documents for interfaces to, and loads imparted upon, building structure+ Common Components, Standard Procedures, Documentatio$ Configurable components used in multiple product offerings+ Generated or revised standard fabrication and procedural documents+ Developed requirements, testing, and acceptance criteria for supplier coatings and finishes+ Developed specification documents for critical machine components+ Assisted with integration of product design management system. Installation and Assembly: Worked with installers to improve processes on standard offerings. Worked with fabricators to improve component designs and perform cost analyses and comparisons. Created manufacturing drawings and sequenced assembly instructions to ensure the machines can be assembled. # Engineering Highlights: THE LARGEST WIND TUNNEL IN THE WORLD Designing the largest wind tunnel in the world comes with special ## challenges and considerations+ 32 foot in diameter and 104 foot heigh in the flight chamber+ A machine that dwarfs all other designs, including a 10-story structure with 16 fans generating more than 7 mega-watts of power+ Huge parametric models in SolidWorks including thousands of unique components. Worked with aerodynamicists to develop multi-story machine components that met airflow requirements. ## Designed components with access for maintenance+ Load-bearing supports and tensioning methods integral to the airflow space, and fairings and bull-noses to smooth transitions ## and provide quality airflow. * * * Prepared documentation and participated in first-article approval and prototype/mock assembly of selected components Worked with structural engineers to provide machine loads for, and to accept loads imparted by, the structure. DEI provided critical analysis and simulation of loads through machine components to support enormous wind load forces on an order of magnitude larger than previous designs. ## WIND TUNNEL ON A CRUISE SHIP Worked with challenging architectural and structural interfaces Developed solutions for critical geometry and weight-loading requirements with limited space availability Develop and implement new integrated component structure support features and methods Developed and implemented new orientations for legacy components in design and solved challenges associated Developed and implemented seals for component interfaces Developed and implemented accessibility features for maintenance Identified corrosion and safety issues and provided features and guidance for prevention. Product Development & Design Engineering Market Driven Product Development from Concept to Manufacture As product life cycles continue to get shorter, the need for new product innovation is relentless. If you miss opportunities to bring innovative solutions to market, your company can quickly become irrelevant. Innovation is no longer an option for growth, but a requirement for survival. And sadly, studies now suggest nearly half of the resources companies devote to the development of new products are spent on products that ultimately fail. Deaton Engineering can help you develop a strategic plan for product and technology investment decisions based on your needs. We follow a phase-based approach to product development and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Optimizing Designs for Manufacturability & Reliability At the onset of a project, Deaton Engineering works with you to carefully define the goals, user requirements, and functional specifications. We examine how the product will be used, the quantities needed, how Product Life Cycle Deaton Engineering can prepare your product for successful offshore manufacturing. At the onset of a project, Deaton Engineering works with you to carefully define the goals, user requirements, and functional specifications. We examine how the product will be used, the quantities needed, how and where the product will be manufactured, and which certifications and classifications are required. User interface design Feasibility and Cost Analysis After the product is defined, material options, manufacturing techniques, and locations are evaluated. We assess how the product can be designed within a specified budget and manufactured at a target price. Product Development and Design Engineering Services SolidWorks & ProE 3d and parametric design Product engineering Digital prototyping Rugged design Human factors design Marketing & functional prototypes Rugged design Computer aided design (CAD) Solid modeling 3d and parametric design Computer aided design (CAD) Product packaging Product engineering Solid modeling Mechanical design Electrical & electronic design Plastic & metal design User centered design Plastic & metal design User centered design Design for shock & vibration Design for manufacture (DFM) Design for UL & CE standards Enclosure design Electronics packaging Design for validation Design optimization, (FEA) Enclosure design Electronics packaging User requirements & functional specifications Concept development Design for UL & CE standards Enclosure design User requirements & functional specifications Concept development Industrial design Design for usability & user experience Design optimization, (FEA) Medical device design Medical device design Contract manufacturing services Engineering services list Product development experience Product development experience ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Step Into the Future # Deaton Engineering Designs Athletic Shoe Insert to Enhance Athletic and Rehabilitation Performance. [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-medhab.pdf) ![Deaton Designs a smart shoe insert with a small footprint](https://www.deatonengineering.com/images/header-runner.jpg) ## The Client: MedHab, LLC & RPM2 MedHab develops wearable technology – insoles that measure and monitor various metrics, giving medical care prescribers the ability to customize rehabilitation protocols to meet patients’ needs. Marketed as StepRite®, the device can measure body weight, force, gait, and flexibility in lower extremities using embedded sensors. Utilizing the same technology, MedHab’s subsidiary RPM2 has developed a set of apps that, when paired with the athletic insoles, can measure an athlete’s bilateral equivalence, weight distribution and range of motion. Athletes whose legs are bilaterally in sync are faster, stronger, and perform better at a higher level. RPM2 is an official Training Footbed Partner for USA Triathlon. Founded in 2008 and based in Fort Worth, TX, MedHab is a privately held company. ![](https://www.deatonengineering.com/images/logo-medhab.png) ![](https://www.deatonengineering.com/images/logo-rpm2.png) ## The Challenge: Design a small footprint smart shoe insole system. In 2010, MedHab approached Deaton Engineering (DE) to develop a proof of concept system in order to verify the feasibility of such a rehabilitation device. The main challenge was implementing all the necessary sensors and communication devices into a package small enough not to hinder a patient or athlete’s performance during daily use. The athletic insole system needed to withstand the wear and tear present inside athletes’ and patients’ shoes, while providing a reliable Bluetooth connection to a nearby device in order to sample data at up to 100Hz from a set of force sensors, a 3-axis accelerometer, a 3-axis gyroscope, and a 3-axis magnetometer. ## The Solution: Miniaturized Smart Inserts & App ![](https://www.deatonengineering.com/images/photo_medhab2.jpg) From the initial proof of concept (which was the size of a shoe box and powered off of 9V batteries, paired with passive insoles connected via ribbon cables) evolved a fully wireless device utilizing the latest in lithium polymer power technology and inductive charging miniaturized to fit inside a shoe insert. DE developed a hardware system utilizing the latest in: low-power management, induction charging, Bluetooth communication, multi-sensor packaging, onboard memory, and BGA technology. Each insole housed a set of four force sensors connected to a miniaturized multi-layer PCB, which contained the 9-axis accelerometer/gyro/magnetometer, Bluetooth antenna and transceiver, induction and power management circuit, on-board non-volatile memory, and low-power microcontroller. All of this packaged into a board no bigger than a stick of gum. DE developed custom firmware that allowed the insoles to communicate wirelessly to mobile devices. DE also developed the app backbone and APIs for Android and iOS devices, later used by RPM2 to create their own control apps. ## Engineering Highlights: - Fully encased miniaturized design able to fit into molded insole without external parts. - Low-Power design utilizing lithium polymer rechargeable battery. - Inductive charging capabilities for wireless battery charging. - Bluetooth communication capabilities between the insoles and Android/iOS devices. - 9-axis Accel/Gyro/Magnetometer & active force sensor integration. - Microcontroller-based PCB design. - Firmware and App (Android/iOS) development. ![](https://www.deatonengineering.com/images/photo_medhab1.jpg) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Software Engineering and Process Control ## Maximizing Efficiency with Information Management and Superior Control Systems For years, plant engineers have utilized just enough process control data to manage ![National Instruments Certified System Partner](https://www.deatonengineering.com/images/ni_logo.png)the plant's operations. But now, market demands, regulatory pressures, and slimmer margins have led the best manufacturers to leverage plant floor data at the enterprise level to drive real-time strategic decisions. Better information at your fingertips can set your business apart by allowing you to efficiently and cost-effectively produce high quality products. Deaton Engineering’s software and process engineering experts can deliver the process control solution you need to make your operation excel. Whether it’s a completely new system or just an upgraded component, we can configure it to meet the needs of your process. Our experts team with you to develop systems that preserve margins, speed the order-to-cash cycle, and maximize your return on assets. ![Complex Machine Design](https://www.deatonengineering.com/images/header-software-eng.jpg) ## Software Engineering, Process & Control Software, and Data Management ### Control Systems and Hardware We specialize in providing professional-grade control solutions for complex environments using many development platforms. We design and build systems that are highly efficient, network-enabled, and secure. ### Custom Test Systems and Data Acquisition Deaton Engineering provides vast experience with [automated equipment](https://www.deatonengineering.com/services/automation.php), control systems, [test and measurement](https://www.deatonengineering.com/services/customtest.php) hardware, and a variety of software development tools such as Microsoft Visual Studio, LabWindow CVI, and SCADA. ### Secure User Interface Development You can rely on Deaton Engineering to provide secure access for any type of system. We apply a risk-based approach to electronic records and signatures that allows companies to comply with [21 CFR, Part 11 requirements](https://www.deatonengineering.com/services/validation.php). ## Software Engineering & Process Control Services - Software engineering - Control software & systems - Process control - Process software - Control system engineering - Software development - Software automation - Data acquisition systems (DAQ) - Microsoft Visual Studio - LabVIEW development - National Instruments (NI) development - Supervisory control and data acquisition (SCADA) - Human machine interface (HMI) - Programmable logic controller (PLC) - Parallel architecture core (PAC) - Embedded system controls & design - Motion controls - Vision systems - Windows based GUI applications - Process controls - Programming languages: C++ to Wonderware - National Instruments Certified System Partner - Advanced algorithm solutions - Automated test stations - [Process engineering services list](https://www.deatonengineering.com/services/softwareengineering.php#) - [Process and manufacturing equipment list](https://www.deatonengineering.com/services/softwareengineering.php#) - [Engineering services list](https://www.deatonengineering.com/services/softwareengineering.php#) - [FDA, regulatory and safety services list](https://www.deatonengineering.com/services/softwareengineering.php#) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/softwareengineering.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/softwareengineering.php#carouselExampleIndicators) #### FAQs: What software engineering and process control services does Deaton Engineering offer in Texas? Deaton Engineering offers a range of services, including: - Control Systems and Hardware: Designing professional-grade, secure, and network-enabled control solutions. - Custom Test Systems and Data Acquisition: Developing automated equipment and control systems and utilizing tools like Microsoft Visual Studio and SCADA. - Secure User Interface Development: Providing secure access solutions that are compliant with regulatory requirements such as 21 CFR, Part 11. How do these services benefit Texas manufacturers? By implementing advanced software and process control systems, Texas manufacturers can: - Enhance Efficiency: Streamline operations and reduce downtime. - Improve Product Quality: Achieve consistent and high-quality production outcomes. - Ensure Compliance: Meet industry standards and regulatory requirements effectively. What platforms and tools does Deaton Engineering utilize? They specialize in various development platforms, including: - Microsoft Visual Studio - LabVIEW Development - National Instruments (NI) Development - Supervisory Control and Data Acquisition (SCADA) - Human Machine Interface (HMI) - Programmable Logic Controller (PLC) How can Texas businesses collaborate with Deaton Engineering for software engineering projects? Businesses can reach out to [Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visit their Georgetown, Texas headquarters, a suburb of Austin, to discuss software engineering and process control needs. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. FEA - Finite Element Analysis & Design Optimization Evaluate, Analyze, and Optimize Performance and Reliability of Product Design and Manufacturing Processes To successfully deploy new products, you have to move quickly to get an edge in the market. And while product life cycles get ever shorter, the cost of warranty and service is on the rise. The traditional design-prototype-test approach to new product development can be slow and inefficient when problems are encountered. Deaton Engineering uses Finite Element Analysis (FEA) to accurately model products and processes. Our techniques can measure performance, reliability, wear points and predict failures long before you commit to tooling or start to build. We are adept at helping companies improve profitability by dramatically reducing development time, rework and quality issues. Our approach will help you speed up the design process through rapid optimization. Design, Simulate and Virtually Test with FEA Services Our goal is to reduce product development costs and improve quality. FEA helps solve design challenges without arduous manual iterations or prototyping. Experienced mechanical engineers verify all FEA findings against empirical test data, simplified models, and classical calculations to ensure accuracy. 3-D modeling is also used to validate designs. Computational Methods to Support Regulatory Filings for Medical Devices Utilize FEA to reduce product development costs, limit liability risk, reduce time to market, and support FDA 510k filings. Identify and analyze worst-case implantable Utilize FEA to reduce product development costs, limit liability risk, reduce time to market, and support FDA 510k filings. Identify and analyze worst-case implantable device size for use in mechanical testing. Verify radial force, anchoring, dynamic compliance, and fatigue loading conditions. FEA & Design Optimization Services Anchoring and fatigue loading conditions Design verification and validation Design verification and validation Thermal ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Case Study: # Validation of New Pharmaceutical APCS is in the Bag [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-apcs.pdf) ![Pharmaceutical Automation case study header](https://www.deatonengineering.com/images/header-pharma.jpg) ## The Need: Part 11 Compliant Validation of an Automated Process Control System Pharmaceutical companies must validate quality-affecting computerized systems in accordance with the FDA's ruling under 21 CFR Part 11. The high level of process control required for Good Manufacturing Practice compliance makes Automated Process Control Systems (APCS) one of the most critical applications of this requirement. Deaton Engineering performs validation services for computer systems and manufacturing equipment, and our work has repeatedly stood up to the scrutiny of FDA auditors. This case study was performed for a major pharmaceutical manufacturer headquartered in the US that specializes in the manufacture of sterile products. ## The Challenge: Validate the Automated Process Control System of a New Autofiller System Validate the automated process control system (APCS) of a high-volume packaging machine designed to form, fill, and seal bags containing a drug product solution. The APCS consisted of five Human-Machine Interfaces (HMIs), three Programmable Logic Controllers (PLCs), and an array of sensors to control the process. The machine was a new design for the customer, acquired to meet the production demands of a new product line. If successful, it would eliminate the need for three other processes used to produce similar products. The project presented a number of challenges. There was very little experience with the machine, so the technology would have to be fully reviewed and understood. In addition, the entire validation would have to be completed under a tight deadline for inclusion in a new drug application (NDA) filing. ## The Solution: Validation Ready for FDA Review ![](https://www.deatonengineering.com/images/photo-pharma2.jpg)Deaton Engineering quickly developed a validation plan to identify the scope, responsibilities, strategy, and technical challenges for the project using our total quality approach to validation. Our engineering experts were able to review the entire system to assess potential risks and identify technical hurdles that might be encountered. Deaton Engineering worked with the customer to create a functional specification for the control system, a documented risk assessment to analyze potential hazards and existing mitigations, a design specification for the entire machine, and installation and operational qualification protocols. Each validation experiment was executed with minimal impact on client production. A validation report - prepared in accordance with the FDA's expectations for current Good Manufacturing Practices - was submitted to the customer detailing each experiment, its results and conclusions. ![](https://www.deatonengineering.com/images/photo_pharm_1.png)![](https://www.deatonengineering.com/images/photo_pharm_3.png)![](https://www.deatonengineering.com/images/photo_pharm_2.png) ## Engineering Highlights: - Provided the professional knowledge base necessary to conduct a thorough risk assessment on a new technology - Delivered validation services that have been proven to meet the FDA's expectations for GMP manufacturers. - Report was reviewed in its entirety by the FDA without inquiries or comments. - Project completed and report delivered in time for NDA submission. ![](https://www.deatonengineering.com/images/photo-pharma.jpg) 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![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Clean Energy Made Safer: # Deaton Designs & Builds Ultrasonic Deterrents to Prevent Bat Fatalities at Wind Farms. [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-batcon.pdf) ![Deaton Designs & Builds Ultrasonic Deterrents to Prevent Bat Fatalities at Wind Farms](https://www.deatonengineering.com/images/photo_batcon1.jpg) ## The Client: Bat Conservation International, Inc. Bat Conservation International, Inc. is on a mission to conserve bats and their ecosystems across the world. BCI combines science-based conservation efforts, research, and education to ensure that the bat population is protected now and into the future. Founded in 1982 and based in Austin, TX, BCI boasts a staff of more than 30 biologists, educators and administrators, and is supported by members in some 60 countries. As wind energy continues to grow as an alternative energy source, the toll of wind turbines on wildlife – particularly bats and birds – is a major concern for BCI. BCI created the Bats and Wind Energy Cooperative (BWEC) along with the U.S. Fish & Wildlife Service, the American Wind Energy Association (AWEA), and the National Renewable Energy Laboratory (NREL, under the direction of the U.S. Department of Energy). BWEC’s focus is to reduce, to the greatest extent practicable, the number of bat fatalities at wind-energy sites. ![](https://www.deatonengineering.com/images/logo-batcon.svg) ## The Challenge: Design and Build Ultrasonic Deterrents In 2009, BCI began working with Deaton Engineering (DE) to complete the design and build of an ultrasonic deterrent system to be mounted to a wind turbine with little or no modifications to the turbine. BCI had performed tests with early-generation devices at ground level in the years prior, but did not have a system that could be manufactured and deployed directly on to wind turbines. The deterrent system needed to withstand the harsh environment present at wind-energy sites, while providing adequate coverage of the turbine with sufficient amplitude of ultrasonic output over a frequency range of up to 100 kHz. ## The Solution: Wind Turbine-Installed Bat Deterrent System ![](https://www.deatonengineering.com/images/photo_batcon2.jpg) DE developed an algorithm to generate white noise over a frequency range of 10 kHz to 100 kHz, and implemented the algorithm with a microcontroller-based PCB design and a custom amplifier circuit. DE designed enclosures that held up to harsh weather while still maintaining the pressure equalization required to allow the ultrasonic transducers to function. Each enclosure housed 16 ultrasonic transducers. DE developed a mechanical mounting system that utilized existing features on the nacelle of the wind turbine and secured 8 ultrasonic deterrents in place around the nacelle. DE designed a regulating, current-limiting 300 VDC power supply to provide power to the amplifier circuits. DE manufactured bat deterrent systems and installed them on 10 wind turbines at a wind farm in Pennsylvania for field tests in 2009 and 2010. Deterrents were also shipped to the UK for testing in church buildings with unwanted bat populations. In 2013, DE modified the deterrent system slightly for a field test at a macadamia nut farm in Hawaii. All of these tests produced encouraging results, suggesting that ultrasound is a promising method of reducing bat fatalities at wind-energy sites. In 2014, DE and BCI embarked on the design of a new generation of the ultrasonic bat deterrent system. Still in progress, this design effort will add alternate ultrasonic waveforms (white noise over adjustable ranges, single frequencies, pulsing modes, frequency sweeps), increased coverage through new mounting geometries, increased effective range through improved amplifier design, and remote control & monitoring. ## Engineering Highlights: - Power and amplified signal distribution for 128 ultrasonic transducers per wind turbine - No nacelle modifications required for installation (except for cable entry in some cases) - Remote control and monitoring (in development) - Automatic recovery modes - Microcontroller-based PCB design - Firmware development ![](https://www.deatonengineering.com/images/photo_batcon3.png) # Biomedical Engineering and Medical Device Design Recent advances in technology have opened the door to many exciting new product opportunities for medical device firms. But competitive pressures and strict regulatory requirements make it tougher than ever to bring a new product to market. In addition, Medicare and insurance cutbacks on patient reimbursement are putting pressure on margins. Deaton Engineering applies a risk-based approach to medical device manufacturing. This technique can deliver substantial improvements in productivity while maintaining the highest assurance of product and human safety. We deliver cost-effective, FDA-compliant solutions by assisting you in developing a plan to meet your goals. We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives, whether it's a mechanical design, a production scale-up, a major automation project, or a plant expansion. ## Medical Device Design, Validation, Manufacturing Automation, and Machine Design ### Medical Device Design Deaton Engineering is experienced with the FDA's requirements for medical devices. We incorporate good documentation practices and validation strategies into our designs. We consider the impact of the design on manufacturing techniques, cost control, cleaning, and sterilization procedures. Our engineering staff can produce your medical device prototypes and provide documentation for 510K submittals, and UL and CE certification. ### Risk-Based Validation Engineering Services Deaton Engineering manages the validation process by developing a strategy that includes requirements, risks, and test procedures to ensure compliance with good manufacturing practices. Deaton Engineering can develop Installation, Operation, and Performance Qualification protocols for any type of manufacturing process, facility or equipment. ### Computational Methods to Support Regulatory Filings for Medical Devices Utilize FEA to reduce product development costs, limit liability risk, reduce time to market, and support FDA 510k filings. Identify and analyze worst-case implantable device size for use in mechanical testing. Verify radial force, anchoring, dynamic compliance, and fatigue loading conditions. ### Manufacturing Automation & Machine Design Deaton Engineering designs fully automated manufacturing systems that incorporate industrial robots, vision systems, and QC testing. We specialize in building turnkey process and equipment solutions that are reliable, cost-effective, and GMP compliant. ## Biomedical Engineering & Design Services Medical device design Prototypes Cardiovascular device design Design for verification and validation Orthopaedic design Development of Class I, Class II, & Medical electronics device design Class III medical devices Orthopaedic implant design Quality system integration Orthopaedic surgical device design Orthopedic device design Surgical instrumentation design & prototyping Computational testing Premarket notification 510(k) Identifying worst-case device sizes Premarket approval (PMA) In vivo loading conditions Implantable design; spinal, orthopaedic, neurological, dental, & Anchoring and fatigue loading conditions cardiovascular Design verification and validation Human factors engineering & design Medical device engineering Device master record (DMR) Medical device product design list Concept development Engineering services list User requirements and functional specifications Validation engineering services list Solid models FDA, regulatory and safety services list ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Step Into the Future # Deaton Engineering Designs Athletic Shoe Insert to Enhance Athletic and Rehabilitation Performance. [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-medhab.pdf) ![Deaton Designs a smart shoe insert with a small footprint](https://www.deatonengineering.com/images/header-runner.jpg) ## The Client: MedHab, LLC & RPM2 MedHab develops wearable technology – insoles that measure and monitor various metrics, giving medical care prescribers the ability to customize rehabilitation protocols to meet patients’ needs. Marketed as StepRite®, the device can measure body weight, force, gait, and flexibility in lower extremities using embedded sensors. Utilizing the same technology, MedHab’s subsidiary RPM2 has developed a set of apps that, when paired with the athletic insoles, can measure an athlete’s bilateral equivalence, weight distribution and range of motion. Athletes whose legs are bilaterally in sync are faster, stronger, and perform better at a higher level. RPM2 is an official Training Footbed Partner for USA Triathlon. Founded in 2008 and based in Fort Worth, TX, MedHab is a privately held company. ![](https://www.deatonengineering.com/images/logo-medhab.png) ![](https://www.deatonengineering.com/images/logo-rpm2.png) ## The Challenge: Design a small footprint smart shoe insole system. In 2010, MedHab approached Deaton Engineering (DE) to develop a proof of concept system in order to verify the feasibility of such a rehabilitation device. The main challenge was implementing all the necessary sensors and communication devices into a package small enough not to hinder a patient or athlete’s performance during daily use. The athletic insole system needed to withstand the wear and tear present inside athletes’ and patients’ shoes, while providing a reliable Bluetooth connection to a nearby device in order to sample data at up to 100Hz from a set of force sensors, a 3-axis accelerometer, a 3-axis gyroscope, and a 3-axis magnetometer. ## The Solution: Miniaturized Smart Inserts & App ![](https://www.deatonengineering.com/images/photo_medhab2.jpg) From the initial proof of concept (which was the size of a shoe box and powered off of 9V batteries, paired with passive insoles connected via ribbon cables) evolved a fully wireless device utilizing the latest in lithium polymer power technology and inductive charging miniaturized to fit inside a shoe insert. DE developed a hardware system utilizing the latest in: low-power management, induction charging, Bluetooth communication, multi-sensor packaging, onboard memory, and BGA technology. Each insole housed a set of four force sensors connected to a miniaturized multi-layer PCB, which contained the 9-axis accelerometer/gyro/magnetometer, Bluetooth antenna and transceiver, induction and power management circuit, on-board non-volatile memory, and low-power microcontroller. All of this packaged into a board no bigger than a stick of gum. DE developed custom firmware that allowed the insoles to communicate wirelessly to mobile devices. DE also developed the app backbone and APIs for Android and iOS devices, later used by RPM2 to create their own control apps. ## Engineering Highlights: - Fully encased miniaturized design able to fit into molded insole without external parts. - Low-Power design utilizing lithium polymer rechargeable battery. - Inductive charging capabilities for wireless battery charging. - Bluetooth communication capabilities between the insoles and Android/iOS devices. - 9-axis Accel/Gyro/Magnetometer & active force sensor integration. - Microcontroller-based PCB design. - Firmware and App (Android/iOS) development. ![](https://www.deatonengineering.com/images/photo_medhab1.jpg) Software Engineering and Process Control Maximizing Efficiency with Information Management and Superior Control Systems For years, plant engineers have utilized just enough process control data to manage the plant's operations. But now, market demands, regulatory pressures, and slimmer margins have led the best For years, plant engineers have utilized just enough process control data to manage the plant's operations. But now, market demands, regulatory pressures, and slimmer margins have led the best manufacturers to leverage plant floor data at the enterprise level to drive real-time strategic decisions. Better information at your fingertips can set your business apart by allowing you to efficiently and cost-effectively produce high quality products. Deaton Engineering’s software and process engineering experts can deliver the process control solution you need to make your operation excel. Whether it’s a completely new system or just an upgraded component, we can configure it to meet the needs of your process. Our experts team with you to develop systems that preserve margins, speed the order-to-cash cycle, and National Instruments Certified System Partner can configure it to meet the needs of your process. Our experts team with you to develop systems that preserve margins, speed the order-to-cash cycle, and maximize your return on assets. Software Engineering, Process & Control Software, and Data Management Control Systems and Hardware We specialize in providing professional-grade control solutions for complex environments using many development platforms. We design and build systems that are We specialize in providing professional-grade control solutions for complex environments using many development platforms. We design and build systems that are highly efficient, network-enabled, and secure. Custom Test Systems and Data Acquisition Deaton Engineering provides vast experience with automated equipment, control systems, test and measurement hardware, and a variety of software development Deaton Engineering provides vast experience with automated equipment, control systems, test and measurement hardware, and a variety of software development tools such as Microsoft Visual Studio, LabWindow CVI, and SCADA. You can rely on Deaton Engineering to provide secure access for any type of system. We apply a risk-based approach to electronic records and signatures that allows companies to comply with 21 CRF, Part 11 requirements. Software Engineering & Process Control Services Software engineering Control software & systems Control software & systems Process control Process control Process software Process control Process software Control system engineering Control system engineering Software development Software development Software automation Parallel architecture core (PAC) Embedded system controls & design Embedded system controls & design Motion controls Data acquisition systems (DAQ) Microsoft Visual Studio Software automation Data acquisition systems (DAQ) Motion controls Vision systems National Instruments (NI) development Supervisory control and data acquisition (SCADA) Supervisory control and data acquisition (SCADA) Human machine interface (HMI) Microsoft Visual Studio LabVIEW development Windows based GUI applications Process controls Human machine interface (HMI) Programmable logic controller (PLC) Vision systems Windows based GUI applications Programmable logic controller (PLC) Process controls Programming languages: C++ to Wonderware National Instruments Certified System Partner National Instruments Certified System Partner Advanced algorithm solutions Process controls Programming languages: C++ to Wonderware Advanced algorithm solutions Automated test stations Process engineering services list Process and manufacturing equipment list Process and manufacturing equipment list Engineering services list Engineering services list FDA, regulatory and safety services list FDA, regulatory and safety services list ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Battle Ready: # Deaton Engineering Creates a Military Hardened Design for Dell & US Air Force [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-tbmcs.pdf) ![Ruggedized Deployable Network Hardware](https://www.deatonengineering.com/images/header-case-study-tbmcs.jpg) ## The Client: Dell Defense Services Dell Inc. designs, develops, manufactures, markets, sells and supports a wide range of computer systems and services customized to meet customer requirements. Dell’s products include servers, storage components, workstations, networking products, notebooks, desktop computers, printers, imaging systems, software, peripherals, and support services. The Dell Defense Services group develops enterprise hardware solutions for government applications. These products are uniquely integrated and designed for semi-mobile use in conditions that exceed normal operating ranges. ![](https://www.deatonengineering.com/images/logo-dell.svg) ## The Challenge: Design and Build a Ruggedized Deployable Network The US Air Force contracted Dell to produce an integrated deployable network system named Theater Battle Management Core Systems (TBMCS). The system components would be mounted in hardened cases, stabilized with custom hardware, and interconnected through signal entry panels (SEPs) that provide convenient access to internal cable ports. Rather than parse this work out to multiple design, machining, and manufacturing firms, Dell hired Deaton Engineering (DE) to design and manufacture the custom hardware, integrate the complete product solution and ship it direct to the customer. ## The Solution: A Rugged Mobile Network ![](https://www.deatonengineering.com/images/photo_tbmcs_4.jpg) Innovative designs were created to stabilize the contents of each case. Deaton Engineering developed a unique wedge bracket, support plate and redundant tie-down strap to secure internal components. The final design enabled all support hardware to be installed or removed using a single, standard tool provided with each product. A strain relief bracket was also developed to secure power cords on components lacking a strain relief mount. DE engineers created custom-labeled SEPs mounted at the rear of the case to provide a single interface for connectivity. The panels provided the user with convenient access in addition to significantly reducing time required for setup and configuration in the field. Finally, the DE manufacturing group integrated the entire suite by assembling each unit and performing a quality assurance inspection prior to shipment. ## Engineering Highlights: - Designed innovative stabilization hardware meeting the military’s rigid deployment requirements - Created custom signal entry panels for rapid setup and configuration - Interfaced with customer to meet tight deadlines through prompt attention to design changes - Provided procurement and inventory management of subcomponents - Utilized high-level technicians to assemble and test each unit - Developed several modular solutions for 19” rack ![](https://www.deatonengineering.com/images/photo_tbmcs_3.jpg) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) # Contact Deaton Engineering ### Contact Us reCAPTCHA ### Mailing Address Deaton Engineering, Inc. P.O. Box 569 Georgetown, TX 78627 [(512) 981-6830](tel:+15129816830) (512) 930-9909 fax ### Street Address Deaton Engineering, Inc. Two Sierra Way Street Suite 110 Georgetown, TX 78626 ![](https://maps.googleapis.com/maps/api/js/StaticMapService.GetMapImage?1m2&1i3835800&2i6889445&2e1&3u16&4m2&1u600&2u450&5m6&1e0&5sen&6sus&10b1&12b1&14i47083502&8e1&key=AIzaSyCmL18misQw9KdwqGaw3zHkitj8vG6QF2Y&token=20864) ## Driving Directions ### From Georgetown (North of Austin) - I-35 south through Georgetown. - Take exit 257 for Westinghouse Road. - Turn left at Westinghouse Road and cross over bridge. - Turn left onto the northbound access road and continue north for approx 1 mile. - Look for Georgetown Fireplace and Patio; this is your marker for Sierra Way Street. - Turn right on Sierra Way Street. - The Deaton Engineering Building is the 2nd to last building on the right, Suite 110. ### From Austin - I-35 north to Georgetown. - Take exit 259 for SE Inner Loop (Business 35) - Stay on northbound I-35 access road for approx 1 mile. - Look for Georgetown Fireplace and Patio; this is your marker for Sierra Way Street. - Turn right on Sierra Way Street. - The Deaton Engineering Building is the 2nd to last building on the right, Suite 110. ### From Austin-Bergstrom International Airport (AUS) - Leaving airport turn right onto TX-71 E. - Turn left onto TX-130 Toll N. /TX-45 Toll N. - Take the TX-45 Toll W. exit, Exit # 428B, toward Round Rock - Exit onto I-35 N toward Waco - Exit 259 for SE Inner Loop (Business 35) - Stay on northbound access road for approximately 1 mile - Look for Georgetown Fireplace and Patio; this is your marker for Sierra Way Street - Deaton Engineering is 2nd building on right, Suite 110. (approx. distance 39 miles) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) # Deaton Engineering Site Map **MAIN** - **[HOME](https://www.deatonengineering.com/)** - **[ABOUT US](https://www.deatonengineering.com/about/index.php)** - **[PRODUCTS](https://www.deatonengineering.com/products.php)** - **[CONTACT US](https://www.deatonengineering.com/contact.php)** - **[PRIVACY](https://www.deatonengineering.com/privacy.php)** - **INDUSTRIES** - [Pharmaceutical Engineering](https://www.deatonengineering.com/industries/pharmaceutical.php) - [Food, Beverage & Dairy](https://www.deatonengineering.com/industries/foodbeverage.php) - [Medical Device Design](https://www.deatonengineering.com/industries/medicaldevices.php) - **SERVICES** - [Finite Element Analysis](https://www.deatonengineering.com/services/elementanalysis.php) - [Complex Machine Design](https://www.deatonengineering.com//services/complex-machine-design.php) - [Software Engineering](https://www.deatonengineering.com/services/softwareengineering.php) - [Product Development](https://www.deatonengineering.com/services/productdevelopment.php) - [Process & Facilities Engineering](https://www.deatonengineering.com/services/facilitiesprocess.php) - [Automation Engineering & Robotics](https://www.deatonengineering.com/services/automation.php) - [Test Engineering & QA/QC](https://www.deatonengineering.com/services/customtest.php) - [Validation Engineering](https://www.deatonengineering.com/services/validation.php) - [Mechanical & Electrical Engineering and Machine Design](https://www.deatonengineering.com/services/machineequipment.php) - [Contract Manufacturing Services](https://www.deatonengineering.com/services/lowvolumemanufacturing.php) - **CASE STUDIES** - [MedHab & RPM2](https://www.deatonengineering.com/case_studies/medhab.php) - [MedHab, LLC & RPM2](https://www.deatonengineering.com//case_studies/medhab.php) - [Briggo Coffee Haus](https://www.deatonengineering.com/case_studies/briggo.php) - [Batcon.org](https://www.deatonengineering.com/case_studies/batcon.php) - [Jukka](https://www.deatonengineering.com/case_studies/jukka.php) - [TLA–Bale Tech](https://www.deatonengineering.com/case_studies/bale_tech.php) - [Novelty Ice Cream](https://www.deatonengineering.com/case_studies/ice_cream.php) - [Dell TBMCS](https://www.deatonengineering.com/case_studies/tbmcs.php) - [iFLY](https://www.deatonengineering.com/case_studies/ifly.php) - [Honda Motor Co](https://www.deatonengineering.com/case_studies/honda.php) - [TMGCore](https://www.deatonengineering.com/case_studies/tmgcore.php) - [Ignite! Learning](https://www.deatonengineering.com/case_studies/ignite.php) - [Control System Validation](https://www.deatonengineering.com/case_studies/apcs.php) - [Fan Testing](https://www.deatonengineering.com/case_studies/fan_test.php) - [Film Gauge](https://www.deatonengineering.com/case_studies/machine_build.php) Validation Engineering & FDA Compliance Validation. Compliance. Confidence. Why Validation Matters—and Why Deaton Engineering Is Your Ideal Partner A robust validation program not only ensures regulatory compliance—it sets your organization apart in a competitive market. Effective validation confirms that systems perform as intended, guarantees that products meet the highest standards of quality and safety, and significantly reduces the risk of FDA 483 observations. At Deaton Engineering, we specialize in helping clients succeed across the full spectrum of validation challenges—whether you’re launching a new process, upgrading legacy equipment, or preparing for an audit. We leverage a risk-based, Total Quality Approach rooted in current Good Manufacturing Practices (cGMP), which allows us to deliver results even in the most complex environments. • Pharmaceuticals (oral solid dose, injectables, APIs) • Biopharmaceuticals (cell and gene therapy, biologics) understand your systems and processes. We take the time to assess every interrelated system to develop documentation that stands up to regulatory scrutiny and supports long-term compliance. Industries we support: Validation is not just a checkbox—it’s a continuous improvement tool. From process equipment and control systems to full facility validations, our team is equipped to prevent compliance issues or help remediate them when they occur. With Deaton, you gain a partner committed to quality, compliance, and operational excellence. • Biopharmaceuticals (cell and gene therapy, biologics) • Medical Devices (diagnostics, software-based systems) • CDMOs and CMOs • FDA- and EMA-regulated research labs and startups * * * A Risk-Based Approach to Validation Services Validation Master Planning (VMP) ▪ Development of compliant, risk-based Validation Master Plans ▪ Defines scope, systems impact, scheduling, roles, and responsibilities ▪ Regulatory strategy built for successful inspections Commissioning & Qualification (FUSE CQV) ▪ Full lifecycle qualification: DQ, IQ, OQ, PQ ▪ Utility qualification: Clean Steam, WFI, HVAC, Compressed Air, etc. ▪ Equipment qualification: Autoclaves, Bioreactors, Cleanrooms, etc. ▪ Installation and start-up support Automated Process Control Systems (APCS) ▪ SCADA, PLCs, and DCS qualification ▪ Control systems and Building Management Systems (BMS) Regulatory Inspection & Audit Readiness Risk-Based Assessments & Gap Analysis ▪ System impact assessments ▪ GMP criticality ranking ▪ Remediation strategies for legacy or undocumented ▪ Inspection readiness assessments ▪ Support for FDA/EMA audits ▪ Data integrity assessments ▪ 483/CAPA response support and remediation execution Computer System Validation (CSV) ▪ Remediation strategies for legacy or undocumented systems ▪ Validation of GxP-relevant software applications ▪ Aligns with GAMP 5 guidelines and 21 CFR Part 11 o User Requirements Specification (URS) ▪ Services include: o Audit trail and electronic signature verification o Test planning and execution (IQ/OQ) o Validation reporting and change control support o Risk assessments and traceability matrices ▪ Systems: LIMS, QMS, ERP, MES, Document Management Systems, e-Logbooks, and cloud/SaaS platforms ▪ Execution of validation activities with clear, audit-ready documentation Protocol Development & Execution ▪ Development of IQ, OQ, PQ, FAT, SAT, and custom protocols ▪ Deviation management and change control coordination SOPs & Quality Document Support ▪ Creation, revision, and harmonization of SOPs ▪ Creation, revision, and harmonization of SOPs ▪ Development of validation templates and standardized documentation ▪ Onboarding and training of QA/QC and operational personnel ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Complex Machine Design Do you need to design a complex mega machine or industrial equipment that doesn’t exist? No problem for DE. We’ve been designing and building complex machines for 30 years. Need to redesign existing equipment? We do that too. If it’s never been done before, that’s our sweet spot. If you’re looking for a commodity piece of equipment, we’re not your engineering firm. ![Complex Machine Design](https://www.deatonengineering.com/images/header-complex-mach-des.jpg) ## Some Examples of our work: ![Card image cap](https://www.deatonengineering.com/images/sv-card.jpg) ##### iFLY Largest vertical wind tunnel in the world, 80-foot-tall mega machine, 4 turbo prop fans generating 1 mega-watt of power. One of the largest SolidWorks parametric designs ever attempted. [Case Study](https://www.deatonengineering.com/case_studies/ifly.php) ![Card image cap](https://www.deatonengineering.com/images/baletech-card.jpg) ##### TLA–Bale Tech Design a patented high-speed baling and wrapping system that produces highly compacted cylindrical bales of shredded waste. Creates hermetically sealed high-density cylindrically shaped bales. Bale weight 5,600 - 9,400 lbs. with a density of 1,400 - 1,700 lbs. per cubic yard. Length 50" - 60" and diameter 66" - 74". Cycle time one bale per 80 - 130 seconds; approximately 120 tons/hour. [Case Study](https://www.deatonengineering.com/case_studies/bale_tech.php) ![Card image cap](https://www.deatonengineering.com/images/briggo-card.jpg) ##### Briggo Design & build automated coffee kiosk. The machine replicates the technique used by elite baristas while adding the precision and repeatability that comes with robotics. The standalone coffee kiosk, combines premium coffee ingredients, precise robotic technology, and a mobile ordering platform to deliver coffee exactly how and when the customer likes it. [Case Study](https://www.deatonengineering.com/case_studies/briggo.php) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/complex-machine-design.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/complex-machine-design.php#carouselExampleIndicators) #### FAQs: What complex machine design services does Deaton Engineering offer in Texas? Deaton Engineering specializes in designing and building complex machinery, including: - Custom Industrial Equipment: Developing machines tailored to specific operational requirements. - Redesign of Existing Equipment: Enhancing performance and efficiency of current machinery. - Turnkey Solutions: Providing end-to-end services from concept through manufacturing. Can Deaton Engineering handle projects that have never been done before? Absolutely. Deaton Engineering thrives on innovative challenges, making them ideal for projects lacking off-the-shelf solutions. What are some examples of Deaton Engineering's complex machine design projects in Texas? Notable projects include: - iFLY: Designing the world's largest vertical wind tunnel, an 80-foot-tall structure powered by four turbo prop fans generating 1 megawatt of power. - TLA–Bale Tech: Creating a patented high-speed baling and wrapping system producing hermetically sealed, high-density cylindrical bales of shredded waste. - Briggo: Developing an automated coffee kiosk replicating elite barista techniques with robotic precision. How does Deaton Engineering approach complex machine design projects? Their process includes: - Discovery: Understanding client challenges and goals. - Solution Assessment: Determine if off-the-shelf solutions exist; if not, proceed with custom design. - Economic Evaluation: Assessing the value and impact of solving the problem. - Scope Definition: Collaboratively defining the problem and project scope. - Phased Design Approach: Following a structured process from conceptualization to manufacturing. How can Texas companies start a complex machine design project with Deaton Engineering? Companies can initiate projects by [contacting Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visiting their Georgetown, Texas, a suburb of Austin, office for consultations.  Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. Food, Beverage, and Dairy – Engineering & Automation Engineered Solutions for Food, Beverage and Dairy Production Food and beverage products have become more complex and expensive to produce while globalization and regulatory requirements continue to limit margins. To remain competitive, companies must find innovative ways to produce their products faster, at lower cost, and with minimal waste. Not long ago, a capable maintenance group could design and maintain your process well enough to meet demand. New requirements and technology have made this model expensive at best. Today’s competitive environment requires a shift in design, selection, and deployment of process automation solutions. Deaton Engineering can help in this transition. Our engineering services take you beyond the “trial and error” approach to addressing the source of production and process issues. We design, build, and manage projects — from a single piece of equipment to a major plant expansion. Meeting Regulatory Expectations regarding Product Safety, Quality, and Production Compliance Engineering (FDA, 3-A, USDA, & NSF) Deaton Engineering’s mechanical, electrical, and software engineers are experienced with food and beverage regulatory requirements (FDA, USDA, NSF, and Deaton Engineering’s mechanical, electrical, and software engineers are experienced with food and beverage regulatory requirements (FDA, USDA, NSF, and EFSA) and process requirements (sanitary piping systems and clean-in-place systems). By evaluating your facilities and process systems, we can make recommendations for improvements in production management, recipe management, asset utilization, safety, and monitoring systems to help you evolve your process. Deaton Engineering can help you apply a risk-based approach to regulatory compliance, thereby containing costs and seizing new opportunities. At any point in the production cycle, Deaton Engineering can lead the compliance process by developing and executing strategies that satisfy federal regulations. Our experts will verify the system was installed correctly and functions as designed. Manufacturing & Process Automation and Machine Design Deaton Engineering designs fully automated systems and can incorporate industrial robots, automated process control systems, and in-line monitoring. We integrate Deaton Engineering designs fully automated systems and can incorporate industrial robots, automated process control systems, and in-line monitoring. We integrate off-the-shelf equipment into our designs to build equipment that evolves with your needs. We are experts at developing systems for in-line testing, security, and quality control. All of our equipment and processes are designed for quality. Engineering & Design Services Clean in place systems (CIP) Steam in place systems (SIP) Steam in place systems (SIP) Sterilization in place systems Sterilization in place systems Pasteurization and sterilization processes Pasteurization and sterilization processes Food, beverage, & dairy processing Pasteurization and sterilization processes Food, beverage, & dairy processing Food, beverage, & dairy packaging Food, beverage, & dairy packaging Food, beverage, & dairy manufacturing Material handling systems Plant operations Food engineering Food engineering Cross contamination Food, beverage, & dairy processing Food, beverage, & dairy packaging Food, beverage, & dairy manufacturing Product handling and conveying equipment Ice cream and water ice extrusion nozzle design & fabrication Ergonomics, safety equipment Cross contamination Product handling and conveying equipment Ice cream and water ice extrusion nozzle design & fabrication Ergonomics, safety equipment & machine guarding Sanitary, clean equipment design 3-A, FDA, USDA and NSF standards Retrofitting manufacturing equipment & lines Industrial microwave systems Industrial microwave systems Sanitary, clean equipment design 3-A, FDA, USDA and NSF standards Process & utility piping Plant & site layout 3-A, FDA, USDA and NSF standards Process & utility piping Factory acceptance testing (FAT) Industrial robots Engineering services list Process engineering services list Process and manufacturing equipment list Engineering services list Process engineering services list Facilities engineering services list Facilities engineering services list Validation engineering services list Validation engineering services list ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Process Engineering, Facilities Engineering, and Process & Plant Safety Management ## The Evolution of Process and Facility Engineering Lower margins, rapid change, and limited resources make it difficult to keep pace with increasingly complex process requirements. Deaton Engineering can help you stay focused on your core competencies by managing and implementing process and facility changes for you. Our experts can apply the latest technology to help you gain strategic advantage through [automation](https://www.deatonengineering.com/services/automation.php) and optimization of your manufacturing processes. Deaton Engineering specializes in [developing](https://www.deatonengineering.com/services/machineequipment.php) and integrating equipment to control and improve critical processes. We work in a variety of industries including [food & beverage](https://www.deatonengineering.com/industries/foodbeverage.php), [pharmaceutical](https://www.deatonengineering.com/industries/pharmaceutical.php), [medical device](https://www.deatonengineering.com/industries/medicaldevices.php), semiconductors, and general [manufacturing](https://www.deatonengineering.com/industries/lowvolumemanufacturing.php). We design systems that provide plant managers with real- time access to their manufacturing process data. ![Complex Machine Design](https://www.deatonengineering.com/images/header-process-eng.jpg) ## Providing operational excellence, risk management, and quality-by-design to speed up manufacturing process development, improve product quality, and drive down the cost of goods sold ### Facility Engineering & Design Our mechanical, electrical, and software engineers work with a wide variety of facility, process, and [control](https://www.deatonengineering.com/services/softwareengineering.php) systems. We can provide equipment and utility layouts as well as perform material flow analyses. From concept through commissioning, we provide design solutions that assure process integrity, operational efficiency, and regulatory compliance. ### Process Engineering & Design We take the time to fully understand your facility, process, and software control needs. Our engineers design processes and systems that meet regulatory requirements set forth by the FDA, USDA, EPA, and others. Our designs can incorporate sanitary piping, purified water, water-for-injection, clean-in-place, and many other system requirements. Process tools such as [in-line analysis](https://www.deatonengineering.com/services/customtest.php), production and recipe management, asset utilization, process safety, and material tracking can provide a high level of control and efficiency. ### Validation and Compliance Engineering Our engineers provide turnkey [validation services](https://www.deatonengineering.com/services/validation.php) that cover the entire validation process. We develop and execute qualification protocols for equipment facility systems, and processes. Our documentation packages are extremely thorough and comply with regulatory requirement. Deaton Engineering can perform validations of [automated control systems](https://www.deatonengineering.com/services/softwareengineering.php) in accordance with 21 CFR 11. ### Machine Design & Automation Engineering Deaton Engineering designs fully [automated systems](https://www.deatonengineering.com/services/automation.php) and can incorporate industrial robots, vision systems, [automated process control systems](https://www.deatonengineering.com/services/softwareengineering.php), and [in-line monitoring](https://www.deatonengineering.com/services/customtest.php). ## Process, Facilities, & Safety Engineering Services - Process & facility optimization - Process automation & control - Rugged and modular design - Powder & bulk solids - Process development & design - Quality by design - Process analysis technology (PAT) - FDA, GMP, cGMP compliance & design - Current good manufacturing practice (cGMP) GMP) - Quality assurance & quality control - USP purified water, water for injection (WFI) - Design of experiments - Aseptic process & equipment design - Plant engineering - Contamination control - Electrical area classification - Start up and commissioning - Statistical process control (SPC) - Ergonomics, safety equipment & machine guarding - Industrial microwave systems - Sanitary & clean process design - Process safety and risk management - Hazard analysis (HAZOP) - Hazardous area classification - Process & piping instrumentation diagram (P&ID) - Bulk flow - [Facilities services list](https://www.deatonengineering.com/services/facilitiesprocess.php#) - [Process engineering services list](https://www.deatonengineering.com/services/facilitiesprocess.php#) - [Process and manufacturing equipment list](https://www.deatonengineering.com/services/facilitiesprocess.php#) - [Engineering services list](https://www.deatonengineering.com/services/facilitiesprocess.php#) - [Validation engineering services list](https://www.deatonengineering.com/services/facilitiesprocess.php#) - [FDA, regulatory and safety services list](https://www.deatonengineering.com/services/facilitiesprocess.php#) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/facilitiesprocess.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/facilitiesprocess.php#carouselExampleIndicators) #### FAQs: What process and facilities engineering services does Deaton Engineering offer in Texas? Deaton Engineering specializes in: - Process Optimization: Enhancing manufacturing processes for efficiency and quality. - Facility Design: Planning and designing facilities that meet operational and regulatory requirements. - Process Safety Management: Implementing safety protocols to mitigate risks in manufacturing environments. Can Deaton Engineering assist with integrating new technologies into existing Texas facilities? Yes, Deaton Engineering helps Texas businesses integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact.  Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How does Deaton Engineering ensure compliance with Texas-specific process and facilities engineering regulations? Their engineers design processes and systems that adhere to regulatory requirements set forth by the FDA, USDA, EPA, and Texas state agencies, ensuring compliance with federal and state standards. How can Texas manufacturers collaborate with Deaton Engineering for process and facilities engineering projects? Manufacturers can contact [Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visit their Georgetown, Texas, headquarters, a suburb of Austin, for consultations. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) # Extremely Cool. Very Small. Surprisingly Powerful: Shouldn’t Your New Data Center Be All of the Above? #### When TMGCore, a Texas-based company focused on developing advanced data center hardware and solutions, wanted to bring _revolutionary improvements to data center design and operation_, they turned to Deaton to make their extraordinary vision… real. How cool is that? [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-tmgcore.pdf) ![TMGCore OTTO](https://www.deatonengineering.com/images/photo-tmgcore-ottos.png) ## The Client: TMGCore _TMGcore collaborates with global industry experts to design, create, and commercialize the next generation of high-performance computing solutions._ ![](https://www.deatonengineering.com/images/logo-tmgcore.png) High-performance computing (HPC) _used to be_ (back in the late 1990s and early 2000s) the exclusive domain of university-based and federally funded national laboratories. Think: Sprawling, old-school, expensive data centers that were anything but energy-efficient. Because of greater volumes of data (requiring sophisticated analytics), lower hardware costs, and the arrival of machine learning and AI, _the opportunity and need_ for HPC has gone mainstream. It’s the best way for your business to keep up with ever-more-demanding customers. Because, let’s face it, we’re all in the data and analytics business now. Until recently, though, there’s been an open question: _If the need for HPC is obvious—and it is—how do you get a new data center that fully addresses your requirements for, among other things, a smaller footprint plus lower capital and operational expenditures?_ ## The Challenge: Understand, Design, and Build the High-Density Data Center At Deaton, we’re comfortable going where nobody has gone before. And that’s what TMGCore invited us to do. We are thankful for such invitations. TMGcore hired us to design, engineer, build prototypes, and create a DFM package for a high-density data center using _two-phase liquid immersion cooling technology._ TMGCore’s OTTO platform had to deliver first-of-their-kind improvements so that companies could deploy infrastructure at unprecedented densities beyond the threshold of traditional air-cooled strategies. Companies (TMGCore clients) realize they need the business-transforming power of high-performance computing. And the words “reliable,” “scalable,” “affordable,” “automated,” “environmentally friendly,” “cost-efficient” have to be in the mix. _Challenge accepted. Data center redefined._ ## The Solution: Doing What Hasn’t Been Done Before. And Doing It Like You’ve Done It Before TMGcore's OTTO 120 - YouTube Tap to unmute 1x [TMGcore's OTTO 120](https://www.youtube.com/watch?v=qWOBznmtdT8) [TMGcore - Advanced Systems](https://www.youtube-nocookie.com/channel/UCUEKgju36q5K85ONE_DQpmQ) TMGcore - Advanced Systems390 subscribers - _There’s No Substitute for Being First:_ OTTO is the first-of-its-kind, commercial-ready, enterprise-grade, two phase liquid immersion cooling platform. - _Density? Oh, Yeah This Is Dense:_ Our design supports extreme, high-density computing blades consuming up to 6,000 watts per blade. - _Efficiency Pushed to the Max:_ OTTO has high-power flux of 3,750 watts per square foot vs. 150-200 watts per square foot in a typical air-cooled data center. - _Fully Autonomous Operations:_ A marketer might call it “OTTO-Pilot.” But whatever you want to call it, OTTO supports lights-out, self-healing, hands-off operation that enables all aspects of the platform to be remotely administered and monitored. - _Robotic Process Automation:_ Including edge deployments in lights-out facilities. - _Centralized Management:_ The OTTO Manager console is a management interface that enables monitoring and administration of the entire platform. - _Advanced Robotics:_ Deaton’s design fully automates the swap-out of installed blades for new blades while the machine is running. Translation: _Zero down time._ Additionally, we created a process to minimize vapor loss during these hot-swaps. - _Process Controls:_ We developed and implemented process controls, including pressure, temperature, fluid level, relative humidity, and more. - _Proprietary Components:_ We worked with fluid experts to conceptualize, develop, and test a _Vapor Recovery System_ that mitigates elevated pressure and minimizes vapor loss. The system implements a _“pervaporative membrane”_ to allow egress of water vapor from the machine without allowing fluid vapor through. **We could go on and on here, taking you even deeper into all that our collaboration with TMGCore has required or produced:** customizable blades, finite element analysis, material compatibility, safety features, design for integration into a customer facility… and much more. We’re engineers. We love getting into the weeds. The proof though of our successful collaboration is much simpler to detail. Here’s the bottom line: _Our success with OTTO has resulted in our working with TMGCore to develop several of its other machine lines._ _Repeat business is a designed-in part of our Deaton’s success._ ## Engineering Highlights: - **The First in Its Type –** OTTO is a commercial ready, enterprise-grade, two-phase liquid immersion cooling platform. - **Unparalleled Densities –** DE’s design supports extreme high-density computing blades consuming up to 6,000 watts (6 kW) per blade. - **Highly Efficient Machine –** OTTO has high power flux of 3,750 watts/SF vs. 150-200 watts/SF in typical air-cooled data centers. - **Fully Autonomous Operations -** OTTO supports lights-out, self-healing, hands-off operation that allows all aspects of the platform to be administered and monitored remotely. - Robotic Process Automation or remote & edge deployments in lights-out facilities. - **Centralized Management -** The OTTO Manager console is a management interface that allows for the monitoring and administration of the entire OTTO platform. - **Advanced Robotics –** DE’s design fully automates the replacement of installed blades inside the machine with new blades while the machine is running (hot-swapping), and with zero down time. In addition, Deaton created a process to minimize the vapor loss during hot-swaps. - **Process Controls –** Process controls, including pressure, temperature, fluid level, relative humidity, and other controls have been developed and implemented by DE. - **Proprietary Components –** DE worked with fluid experts to conceptualize, develop, and test a Vapor Recovery system that mitigates elevated pressure in the machine and minimizes fluid vapor loss. The system implements a “pervaporative membrane” to allow the egress of water vapor from the machine without allowing fluid vapor through. - **Customizable Blades –** DE developed mechanical, electrical and worked with partners on communications architecture for the blade/machine interface, which allows customers to have the flexibility to use their custom-built blades in the machine. Collaborating with partners of TMG, DE developed an immersed power supply blades providing compute power. - **FEA**: Engineers at DE performed finite element analyses on critical machine components for verification of the design robustness. - **Custom measures and off-the-shelf equipment** were implemented to identify critical process faults and report to control system - **Fluid Choice –** The machine can be filled and operated with several compatible fluids. - **Material Compatibility –** DE conducted research and consulted with subject matter experts on the materials that would be compatible with the specialty fluids to avoid chemical reactions and/or physical changes or damages to the fluid, parts and components. - **Safety Features –** DE performed risk assessments to deliver design features that mitigate electrical, mechanical, and health safety issues related to operation of the machine. - **Redundancy –** Deaton enhanced the reliability of the machine and minimize down time. Redundancy was implemented for most components. - **Design for Integration into Customer Facility –** Deaton’s design supported different types of power, such as 415V and 480V, and different facility water supply lines. - **Design for Manufacturing and Assembly Support –** Deaton worked with high volume manufacturing partners to prepare the machine design for volume manufacturing. - **Prototype Build, Testing, Debugging, Optimization:** DE built a full-size prototype and tested the machine at system, subassembly, and component levels. If any issues arose during the testing, DE’s engineers debugged them, and optimized the performance to meet customer needs. - **HMI (Human Machine Interface) –** In addition to autonomous control, as well as remote manual control, operators of the machine will be able to manually control at the machine via a user-friendly, large, high-resolution touch-screen. - **Documentation –** developed documentation for testing, shipping readiness, installation, commissioning, user operation, maintenance, and many other critical documents. - **Aesthetics –** DE worked with our customer and their partner to include customer’s vision of an aesthetic machine. - **Project Management and Communication –** DE diligently managed the project and created a strong effective communication with our customer, vendors, machine shops, and others. In addition to OTTO 120, the first immersion cooling product of TMGcore, DE has assisted TMGcore to develop several other machine lines with various capacities that met customer needs. #### Case study # Deaton Designs & Builds Ultrasonic Deterrents to Prevent # Bat Fatalities at Wind Farms ### The Client: Bat Conservation International, Inc. Bat Conservation International, Inc. is on a mission to conserve bats and their ecosystems across the world. BCI combines science-based conservation efforts, research, and education to ensure that the bat population is protected now and into the future. Founded in 1982 and based in Austin, TX, BCI boasts a staff of more than 30 biologists, educators and administrators, and is supported by members in some 60 countries. As wind energy continues to grow as an alternative energy source, the toll of wind turbines on wildlife – particularly bats and birds – is a major concern for BCI. BCI created the Bats and Wind Energy Cooperative (BWEC) along with the U.S. Fish & Wildlife Service, the American Wind Energy Association (AWEA), and the National Renewable Energy Laboratory (NREL, under the direction of the U.S. Department of Energy). BWEC’s focus is to reduce, to the greatest extent practicable, the number of bat fatalities at wind-energy sites. ## The Challenge: Design and Build Ultrasonic Deterrents In 2009, BCI began working with Deaton Engineering (DEI) to complete the design and build of an ultrasonic deterrent system to be mounted to a wind turbine with little or no modifications to the turbine. BCI had performed tests with early-generation devices at ground level in the years prior, but did not have a system that could be manufactured and deployed directly on to wind turbines. The deterrent system needed to withstand the harsh environment present at wind-energy sites, while providing adequate coverage of the turbine with sufficient amplitude of ultrasonic output over a frequency range of up to 100 kHz. ## The Solution: Wind Turbine-Installed Bat Deterrent System DEI developed an algorithm to generate white noise over a frequency range of 10 kHz to 100 kHz, and implemented the algorithm with a microcontroller-based PCB design and a custom amplifier circuit. * * * DEI designed enclosures that held up to harsh weather while still maintaining the pressure equalization required to allow the ultrasonic transducers to function. Each enclosure housed 16 ultrasonic transducers. DEI developed a mechanical mounting system that utilized existing features on the nacelle of the wind turbine and secured 8 ultrasonic deterrents in place around the nacelle. DEI designed a regulating, current-limiting 300 VDC power supply to provide power to the amplifier circuits. DEI manufactured bat deterrent systems and installed them on 10 wind turbines at a wind farm in Pennsylvania for field tests in 2009 and 2010. Deterrents were also shipped to the UK for testing in church buildings with unwanted bat populations. In 2013, DEI modified the deterrent system slightly for a field test at a macadamia nut farm in Hawaii. All of these tests produced encouraging results, suggesting that ultrasound is a promising method of reducing bat fatalities at wind-energy sites. In 2014, DEI and BCI embarked on the design of a new generation of the ultrasonic bat deterrent system. Still in progress, this design effort will add alternate ultrasonic waveforms (white noise over adjustable ranges, single frequencies, pulsing modes, frequency sweeps), increased coverage through new mounting geometries, increased effective range through improved amplifier design, and remote control & monitoring. # Engineering Highlights: o Power and amplified signal distribution for 128 ultrasonic transducers per wind turbina o No nacelle modifications required for installation (except for cable entry in some cases\] o Remote control and monitoring (in development\] o Automatic recovery modeY o Microcontroller-based PCB desigd o Firmware development #### Case study # Deaton Engineers Help Briggo Design & Build Automated # Coffee Kiosk ### The Client: Briggo, Inc. Briggo, Inc. is focused on brewing your personalized, perfect cup of coffee, every time. Founded in 2008 in Austin, TX, Briggo is a standalone coffee kiosk, combining premium coffee ingredients, precise robotic technology, and a mobile ordering platform to deliver coffee exactly how and when you like it. Briggo’s goal is to install kiosks in locations where the need for quality coffee is unfulfilled by traditional coffee shops. ## The Challenge: Design and Build an Automated Coffee Kiosk. In 2009, Briggo approached Deaton Engineering (DEI) to transform their vision into a functioning prototype. Each subsequent version of the machine would need to become more complex, starting with a primitive lab unit, progressing to a semi-automated kiosk installed at a commercial location, finally to a fully-automated kiosk. Briggo wanted to replicate the technique used by elite baristas while adding the precision and repeatability that comes with robotics. The machines also had to interact seamlessly with industrial design, middleware and mobile applications that Briggo simultaneously developed during DEI’s design phase. ## The Solution: Semi- and Fully-Automated First Article Kiosks DEI completed work on a functioning lab unit in 2010, and then a semi-automated kiosk was completed and installed at the Flawn Academic Center at the University of Texas in 2011. A Briggo employee attended the kiosk in order to place/retrieve cups and press start, but the kiosk did the rest, utilizing rotary and linear actuators, valves, sensors and custom software. * * * The kiosk created a wide menu of drinks, including brewed coffee, espressos and lattes along with the standard array of additives.espressos and lattes along with the standard array of additives. The kiosk stayed in use until the fully-automated Briggo Coffee Haus replaced it in 2013. DEI worked with Briggo and other partners to create this new coffee experience that no longer required an attendant. The Coffee Haus provided more drink and additive options while significantly reducing the kiosk’s footprint. The Coffee Haus offered significant design upgrades with more motion control, parallel processing, and a modular design. After the installation of the Coffee Haus, DEI assisted Briggo with the transition of further design & maintenance over to their in-house team. # Engineering Highlights: \_ Multi-axis motion controG \_ Precise motion profileC \_ Middleware and mobile application interactioM \_ Control system desigM \_ Signal conditioninJ \_ Data acquisitioM \_ Software developmen\ \_ Safety standards compliance – food & beverage, electrical, fire ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) [![](https://www.deatonengineering.com/images/icn_pdf.gif)](https://www.deatonengineering.com/pdfs/industries/medicaldevices.pdf "Download PDF") # Biomedical Engineering and Medical Device Design Recent advances in technology have opened the door to many exciting new product opportunities for medical device firms. But competitive pressures and strict regulatory requirements make it tougher than ever to bring a new product to market. In addition, Medicare and insurance cutbacks on patient reimbursement are putting pressure on margins. ![Total quality management: define, design, build, validate, and improve.](https://www.deatonengineering.com/images/tqi.png) Deaton Engineering applies a risk-based approach to medical device manufacturing. This technique can deliver substantial improvements in productivity while maintaining the highest assurance of product and human safety. We deliver cost-effective, FDA-compliant solutions by assisting you in developing a plan to meet your goals. We employ a Total Quality Improvement methodology for [design](https://www.deatonengineering.com/services/productdevelopment.php), [validation](https://www.deatonengineering.com/services/validation.php), and [manufacturing](https://www.deatonengineering.com/industries/lowvolumemanufacturing.php). We partner with you to develop and deliver innovative engineering solutions to support your project initiatives, whether it's a mechanical design, a production scale-up, a major [automation project](https://www.deatonengineering.com/services/automation.php), or a [plant expansion](https://www.deatonengineering.com/services/facilitiesprocess.php). ## Medical Device Design, Validation, Manufacturing Automation, and Machine Design ### Medical Device Design Deaton Engineering is experienced with the FDA's requirements for medical devices. We incorporate good documentation practices and validation strategies into our designs. We consider the impact of the design on manufacturing techniques, cost control, cleaning, and sterilization procedures. Our engineering staff can produce your medical device prototypes and provide documentation for 510K submittals, and UL and CE certification. ### Risk-Based Validation Engineering Services Deaton Engineering manages the [validation process](https://www.deatonengineering.com/services/validation.php) by developing a strategy that includes requirements, risks, and test procedures to ensure compliance with good manufacturing practices. Deaton Engineering can develop Installation, Operation, and Performance Qualification protocols for any type of manufacturing process, facility or equipment. ### Computational Methods to Support Regulatory Filings for Medical Devices Utilize FEA to reduce product development costs, limit liability risk, reduce time to market, and support FDA 510k filings. Identify and analyze worst-case implantable device size for use in mechanical testing. Verify radial force, anchoring, dynamic compliance, and fatigue loading conditions. ### Manufacturing Automation & Machine Design Deaton Engineering designs fully [automated manufacturing](https://www.deatonengineering.com/services/automation.php) systems that incorporate industrial robots, vision systems, and QC testing. We specialize in building turnkey process and [equipment solutions](https://www.deatonengineering.com/services/machineequipment.php) that are reliable, cost-effective, and GMP compliant. ## Biomedical Engineering & Design Services - Medical device design - Cardiovascular device design - Orthopaedic design - Medical electronics device design - Orthopaedic implant design - Orthopaedic surgical device design - Surgical instrumentation design & prototyping - Premarket notification 510(k) - Premarket approval (PMA) - Implantable design; spinal, orthopaedic, neurological, dental, & cardiovascular - Human factors engineering & design - Device master record (DMR) - Concept development - User requirements and functional specifications - Solid models - Prototypes - Design for verification and validation - Development of Class I, Class II, & Class III medical devices - Quality system integration - Orthopedic device design - Computational testing - Identifying worst-case device sizes - In vivo loading conditions - Anchoring and fatigue loading conditions - Design verification and validation - Medical device engineering - [Medical device product design list](https://www.deatonengineering.com/industries/medicaldevices.php#) - [Engineering services list](https://www.deatonengineering.com/industries/medicaldevices.php#) - [Validation engineering services list](https://www.deatonengineering.com/industries/medicaldevices.php#) - [FDA, regulatory and safety services list](https://www.deatonengineering.com/industries/medicaldevices.php#) #### FAQs: What services does Deaton Engineering offer to the Medical Device industry in Texas? Deaton Engineering provides a range of services tailored to the Medical Device sector, including: - Medical Device Design: Developing innovative device designs that comply with FDA requirements, cost control, and sterilization procedures. - Risk-Based Validation Engineering: Managing the validation process by developing strategies that include requirements, risks, and test procedures to ensure compliance with good manufacturing practices. - Manufacturing Automation & Machine Design: Design fully automated manufacturing systems incorporating industrial robots, vision systems, and quality control testing to enhance productivity and maintain high safety standards. How does Deaton Engineering ensure compliance with Texas-specific medical device regulations? Deaton Engineering stays abreast of both federal and Texas state regulations governing medical device manufacturing and distribution. They ensure that all projects comply with guidelines set forth by the Texas Department of State Health Services (DSHS), including adherence to state-specific statutes and federal laws adopted by reference. Can Deaton Engineering assist with facility optimization and safety in Texas-based medical device manufacturing plants? Yes, Deaton Engineering offers support services for production systems in FDA-approved facilities across Texas. Their engineers can design, improve, or support systems that run operations, including on-site construction management and start-up support, ensuring efficiency and safety standards compliance. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How does Deaton Engineering approach process automation for Texas medical device companies? Deaton Engineering designs and builds individual equipment or complete manufacturing lines to automate and improve processes. They utilize GAMP-compliant designs to create turnkey solutions that are reliable, cost-effective, and suitable for GMP validation, catering to the specific needs of Texas medical device manufacturers. How can Texas medical device companies initiate a project with Deaton Engineering? Companies can [contact Deaton Engineering here](https://www.deatonengineering.com/contact.php), or by visiting their Georgetown, Texas headquarters, a suburb of Austin, Texas. They offer free consultations to discuss potential projects and provide estimates, facilitating collaboration with Texas-based medical device firms. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. #### Design and Build for Validation # Deaton Engineering Measures Up for Good # Manufacturing Practices ### The Need: Accurate Measurement of Thin Films Transdermal patches have become increasingly popular for the administration of various drugs. While convenient and effective, patches present several challenges to formulation. Timed release of the drug is a function of the patch's surface area and thickness so accurate measurement of these physical dimensions is critical. Recognizing this need, Deaton Engineering agreed to develop a laser measurement gauge capable of making highly accurate measurements of thin films. The gauge would be purchased by a contract formulator for in-process testing of manufactured films impregnated with a drug substance. ## The Challenge: Design a Film-Thickness Measurement Technique The gauge would need to perform continuous thickness measurements of thin film polymer extrusions in a GMP manufacturing environment. The tolerances for film thickness in this application were extremely narrow so innovative techniques would be required. Product not meeting these criteria would be physically marked as out-of-specification. The size of the film and high rate of production would require multiple measurements to be taken across the film and processed in real time. Since it would be used for drug product formulations, the machine would have to be designed for validation and the control system would have to meet 21 CFR Part 11 requirements. ## The Solution: A Validated, In-Line Gauge for Analysis of Film-Thickness Deaton Engineering began by developing specifications to define the function, operation, installation, and acceptance testing of the measurement gauge. A design employing 5 laser displacement sensor pairs controlled by a PC was developed and proven against an application test plan. From these specifications, a turn-key film thickness measurement system was constructed at Deaton Engineering. The measurement gauge was successfully integrated into the customer's process and calibrated by the engineering team. * * * Deaton Engineering's validation team was involved in creating the functional specification of the gauge to ensure that critical functions could be validated in accordance with GMP requirements once installed. A set of protocols were created to challenge the system and ensure it complied with the functional specification. Each validation experiment was successfully executed and the results presented in a report suitable for FDA audit review. # Engineering Highlights: i Technique for making very accurate film thickness measurements successfully developed and provec i The design for validation facilitated a smooth and efficient validation process-including Part 11 compliance validation of the control systeV i Delivery of a turn-key in-line process measurement system ready for GMP application Automation Engineering & Robotics Design, Development, and Implementation of Advanced Automation Systems Manuf acturing is not what it used to be. Competition in today ’s global marketplace is intense, and domestic manuf acturers must work harder than ev er to succeed. Compounding these challenges are customers and retailers that are sav v ier than ev er, demanding lower prices and f aster deliv ery times. To be successf ul, manuf acturers must seek new strategies f or controlling operating costs. While some may abandon domestic f acilities and ship their operations ov erseas, this approach is of ten f raught with challenges. An alternativ e approach is to improv e the ef f iciency of y our current manuf acturing process — right here, right now — with automation. Deaton Engineering helps North American manuf acturing companies dramatically improv e the quality and ef f iciency of their operation through the use of automation, robotics, and other ef f iciency measures that are of ten more cost-ef f ectiv e and prof itable than of f -shoring. Through automation, we can optimize y our capital and labor resources in production, inv entory management, quality control, and warehousing. Not only will y ou become more ef f icient and cost competitiv e, but y ou’ll also maintain tighter control of the operation than with manuf acturing ov erseas. Factory Automation, System Engineering, & Robotics High-end Factory, Equipment, & Process Automation Deaton Engineering designs f ully automated control sy stems that incorporate industrial robots, v ision sy stems, custom hardware, and quality Deaton Engineering designs f ully automated control sy stems that incorporate industrial robots, v ision sy stems, custom hardware, and quality control measurement techniques. Deaton Engineering works with numerous robot manuf acturers to implement automation sy stems encompassing all f orms of robotics including: pick and place, Cartesian, SCARA, and 4 and 6 axis robots. Deaton Engineering integrates robots ideal f or automating applications such as palletizing, machine tending, material handling, packaging, cutting, material remov al, and welding. We can also prov ide testing serv ices f or existing robotic sy stems. Automated Test and Quality Assurance Bridging the automation-to-enterprise gap is about lev eraging manuf acturing data in enterprise decisions. Deaton Engineering designs semi- and f ully - automated Bridging the automation-to-enterprise gap is about lev eraging manuf acturing data in enterprise decisions. Deaton Engineering designs semi- and f ully - automated test dev ices f or manuf acturing lines. We team with y ou to integrate quality control sy stems designed to continuously improv e product quality and increase ef f iciency. Partner with Deaton Engineering for Support & Integration of: Industrial robots 4 and 6 axis Vision sy stems Vision sy stems Laser displacement measurement Laser displacement measurement Motion control sy stems Motion control sy stems Material handling Indexing sy stems Assembly machines Laser marking and processing Bar code scanners Pick & place robots Laser marking and processing Assembly machines PLC and PC machine control Bar code scanners Non contact measurement PLC and PC machine control Serv o & stepper motors Non contact measurement Serv o & stepper motors Material joining sy stems Process and manuf acturing equipment list Process engineering serv ices list Process engineering serv ices list ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ![](https://www.deatonengineering.com/images/build_thumb.jpg)[About Deaton](https://www.deatonengineering.com/about/index.php) ![](https://www.deatonengineering.com/images/partner_icon.jpg)[Partners](https://www.deatonengineering.com/about/partners.php) # Partners ![National Instruments Partner](http://www.deatonengineering.com/images/logo_partner_ni.gif) ### National Instruments: National Instruments transforms the way engineers and scientists around the world design, prototype, and deploy systems for test, control, and embedded design applications. [www.ni.com/company/](http://www.ni.com/company/) * * * ![Solidworks Certified Partner](http://www.deatonengineering.com/images/logo_partner_solidworks.gif) ### SolidWorks: SolidWorks provides intuitive and straightforward 3D CAD tools to help design teams develop better products. [www.solidworks.com/](http://www.solidworks.com/) * * * ![Texas Healthcare & Bioscience Institute (THBI) Partner](http://www.deatonengineering.com/images/logo_partner_thbi.gif) ### THBI: The Texas Healthcare & Bioscience Institute (THBI) is the leading voice of the Texas Healthcare Bioscience Industry and the only provider of statewide resources to our members and the industry. With a focus on lobbying and advocacy as well as industry vitalization, THBI works with government and industry leaders to recruit the life sciences to Texas and to promote effective government legislation on the behalf of the industry at the state and federal level. [www.thbi.com](http://www.thbi.com/)/ * * * ![Texas Life-Sciences Collaboration Center (TLCC) Partner](http://www.deatonengineering.com/images/logo_partner_tlsc.gif) ### Texas Life-Sciences Collaboration Center: The TLCC is a non profit organization meant to attract post-incubation biotechnology and life sciences companies to Georgetown and Central Texas. The center provides wet labs, a nanotechnology Class-100 clean room, basic infrastructure and plans for genomics, proteomics, and bioinformatics product laboratories to schools, universities and member organizations that locate in the center. [www.texaslifesciences.com/](http://www.texaslifesciences.com/) ## Battle Ready # The Clie ~~t: Dell Defe~~ se Services Dell I ~~c. desig~~ s, devel≥ps, m≈ ~~uf≈ctures, m≈rkets, sells ≈~~ d supp≥rts ≈ wide r≈ ~~ge ≥f c≥mputer systems ≈~~ d services cust≥mized t≥ meet cust≥mer requireme ~~ts. Dell’s pr≥ducts i~~ clude servers, st≥r≈ge c≥mp≥ ~~e~~ ts, w≥rkst≈ti≥ ~~s, ~etw≥rki~~ g pr≥ducts, ~~≥teb≥≥ks, deskt≥p c≥mputers, pri~~ ters, im≈gi ~~g systems, s≥ftw≈re, peripher≈ls, ≈~~ d supp≥rt services. The Dell Defe ~~se Services gr≥up devel≥ps e~~ terprise h≈rdw≈re s≥luti≥ ~~s f≥r g≥ver~~ me ~~t ≈pplic≈ti≥~~ s. These pr≥ducts ≈re u ~~iquely i~~ tegr≈ted ≈ ~~d desig~~ ed f≥r semi-m≥bile use i~ c≥ ~~diti≥~~ s th≈t exceed ~~≥rm≈l ≥per≈ti~~ g r≈~ges. # The Ch≈lle ~~ge: Desig~~ ≈~d Build ≈ Ruggedized Depl≥y≈ble Netw≥rk The US Air F≥rce c≥ ~~tr≈cted Dell t≥ pr≥duce ≈~~ i ~~tegr≈ted depl≥y≈ble ~etw≥rk system ~≈med The≈ter B≈ttle M≈~~ ≈geme ~~t C≥re Systems (TBMCS). The system c≥mp≥~~ e ~~ts w≥uld be m≥u~~ ted i~ h≈rde ~~ed c≈ses, st≈bilized with cust≥m h≈rdw≈re, ≈~~ d i ~~terc≥~~ected thr≥ugh sig~~ ≈l e ~~try p≈~~ els (S ~~Ps) th≈t pr≥vide c≥~~ ve ~~ie~~ t ≈ccess t≥ i ~~ter~~ ≈l c≈ble p≥rts. R≈ther th≈~ p≈rse this w≥rk ≥ut t≥ multiple desig ~~, m≈chi~~ i ~~g, ≈~~ d m≈ ~~uf≈cturi~~ g firms, Dell hired De≈t≥~ ~~gi ~~eeri~~ g (D ~~I) t≥ desig~~ ≈ ~~d m≈~~ uf≈cture the cust≥m h≈rdw≈re, i ~~tegr≈te the c≥mplete pr≥duct s≥luti≥~~ ≈~d ship it direct t≥ the cust≥mer. # The Ch≈lle ~~ge: Desig~~ ≈~d Build ≈ Ruggedized Depl≥y≈ble Netw≥rk I~~≥v≈tive desig ~~s were cre≈ted t≥ st≈bilize the c≥~~ te ~~ts ≥f e≈ch c≈se. De≈t≥~~ ~~gi ~~eeri~~ g devel≥ped ≈ u ~~ique wedge br≈cket, supp≥rt pl≈te ≈~~ d redu ~~d≈~~ t tie-d≥w~ str≈p t≥ secure i ~~ter~~ ≈l c≥mp≥ ~~e~~ ts. The fi ~~≈l desig~~ e ~~≈bled ≈ll supp≥rt h≈rdw≈re t≥ be i~~ st≈lled ≥r rem≥ved usi ~~g ≈ si~~ gle, st≈~d≈rd t≥≥l pr≥vided with e≈ch pr≥duct. * * * A strain relief bracket was also developed to secure power cords on components lacking a strain relief mount. DEI engineers created custom-labeled SEPs mounted at the rear of the case to provide a single interface for connectivity. The panels provided the user with convenient access in addition to significantly reducing time required for setup and configuration in the field. Finally, the DEI manufacturing group integrated the entire suite by assembling each unit and performing a quality assurance inspection prior to shipment. # Engineering Highlights: Y Designed innovative stabilization hardware meeting the military’s rigid deployment requirement< Y Created custom signal entry panels for rapid setup and configuratioJ Y Interfaced with customer to meet tight deadlines through prompt attention to design change< Y Provided procurement and inventory management of subcomponent< Y Utilized high-level technicians to assemble and test each uniT Y Developed several modular solutions for 19” rack ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Green Machine: # Case Study - TLA-Bale Tech - Design and Build a Portable Waste Baling System [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-bale_tech.pdf) ![Deaton Engineering Helps Design and Build a Portable Waste Baling System](https://www.deatonengineering.com/images/header-tla-baletech.jpg) ## The Client: TLA - Bale Tech, LLC a subsidiary of Transload America, Inc. TLA - Bale Tech, LLC is a subsidiary of Transload America, Inc. TransLoad was formed in 2002 to own and operate businesses associated with rail-based transportation, handling, recycling and disposal of waste material. The Company's strategy is to satisfy and exploit an increasing need for economical long-haul transportation and disposal of solid waste from large urban centers in the US and Canada where capacity is becoming increasingly limited, to disposal facilities in the Midwest and Southeast where disposal capacity is more abundant and economical. ## The Challenge: Design and Build a Portable Waste Baling System TLA - Bale Tech hired Deaton Engineering, Inc. to design, engineer and produce manufacturing documentation for a portable and robust stretch-wrap baling system. The system needs to be suitable for continuous processing and be portable for standby solutions for unexpected waste management disruptions including: natural disasters, military zones, and economic hardships. The client wants to leverage decades of baling systems and waste management experience to pave the way for the development of portable processing equipment to handle municipal solid waste that is environmentally friendly, operationally efficient, and cost-effective. ## The Solution: Next Generation Bale Tech III Deaton Engineering, along with TLA - Bale Tech, produced the next generation stretch-wrap portable baling system that innovates the handling and delivery of waste commodities. Bale Tech III is a patented high-speed baling and wrapping system that produces highly compacted cylindrical bales of shredded waste. Bale Tech III bales have a standardized weight of 3 tons, when baling municipal solid waste and do not leak or emit odors, making them ideal for long-term storage and multi-modal transportation. ![](https://www.deatonengineering.com/images/photo_bale_tech2.jpg) ![](https://www.deatonengineering.com/images/baletech-render.jpg) ## Engineering Highlights: - Patented stretch-wrap baling technology - Fully automated seamless processing system with remote diagnostic and performance data collection - Portable, safe and simple to install with less than one day set-up time - Creates hermetically sealed high-density cylindrically shaped bales - Bale weight 5,600 - 9,400 lbs with a density of 1,400 - 1,700 lbs per cubic yard - Length 50" - 60" and diameter 66" - 74" - Cycle time one bale per 80 - 130 seconds; approximately 120 tons/hour BaleTech Waste System - YouTube Tap to unmute 1x [BaleTech Waste System](https://www.youtube.com/watch?v=MW3kl23KV1A) [Deaton Engineering](https://www.youtube.com/channel/UCZXmWma7vUQz_5oHQTwH-JQ) Deaton Engineering30 subscribers ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Consistency. Quality. Efficiency: # Deaton Engineering Helps Dell Quality Test 450 Cooling Fans Simultaneously [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-fan_test.pdf) ![Dell/Tyrex case study header](https://www.deatonengineering.com/images/header-fan-test.jpg) ## The Client: Dell Computer Inc. / Tyrex Group Dell Inc. designs, develops, manufactures, markets, sells and supports a wide range of computer systems and services customized to meet customer requirements. Dell’s products include servers, storage components, workstations, networking products, notebooks, desktop computers, printers, imaging systems, software, peripherals, and support services. TyRex Group is a complete manufacturing service and technology solutions provider specializing in the high-tech industry. The TyRex Group provides manufacturing services for cable connectivity, circuit board design, electronic components, hardware and software installation, testing, and other applications. ![](https://www.deatonengineering.com/images/logo-dell.svg) ![](https://www.deatonengineering.com/images/logo-tyrex.png) ## The Challenge: Design and Build An Automated Computer Fan Tester Dell and TyRex engaged Deaton Engineering to develop an automated fixture capable of simultaneously controlling and testing up to 450 fans for use during qualification of new computer cooling fan models. The data acquisition and control system necessitated independent control and monitoring of fan speed and input power. Additionally, the controller was required to recognize and disable a failed fan during testing. Multiple fan sizes and blowers needed to be fixtured and connected to the test system; a common, flexible mounting fixture was required to accommodate fans from 50mm to 92mm in diameter capable of providing power and signal distribution to each fan. ## The Solution: Automated Fan Test Fixture ![](https://www.deatonengineering.com/images/photo_fan_test1.jpg) Deaton Engineering developed designs for the fixture’s circuit boards, fan mounts, power management and cable assemblies. These components were used to create the test device, which was integrated with a standard thermal test chamber. Performance testing included one week of continuous power cycling for all the fans at 70C. Parametric testing was performed at the end of the week, the fans were cycled through their range of speed, while monitoring the speed and power demand of each fan independently. This data was stored on the control computer and used to trend the performance of each of the fans in the test. This cycle of performance testing and parametric testing was repeated for 7 weeks. The first article was built, installed and verified to demonstrate the final product met the design specifications. The designs, drawings, and procedures for building and installing the device were transferred to Tyrex for use with Dell components. ## Engineering Highlights: - Worked with Dell reliability engineers to develop fan tester requirements and specifications - Designed custom test rack capable of handling signal and power requirements necessary to simultaneously control 450 multidimensional fans - Created adjustable mounting bracket to accommodate multiple fan sizes/models without jeopardizing airflow - Designed and developed power distribution which incorporated unique circuit protection, cable routing, and thermal considerations - Assembled transfer documentation package for deployment to Asian manufacturers to meet client needs ![](https://www.deatonengineering.com/images/photo_fan_test2.jpg) #### Case study # Deaton Engineering Helps Design & Build Automated Food Kiosk ### The Client: JUKKA Inc JUKKA was founded on the concept of offering an endless variety of foods to a broad consumer audience where and when convenient for their busy lives. With all the smart technology available, their mission was to harness this, in innovative ways, to accelerate brands and improve consumer experience with foods on the go. ## The Challenge: Reimagining the Vending Machine In 2014, JUKKA approached Deaton Engineering to help bring this vision to life by designing a smart kiosk that can store, heat, and vend a variety of snacks, entrées and desserts. Equally important was form factor, which had to be elegant and unlike the vending machines of the past. Transactions were to be cashless and secure, and customers would have the option of ordering in-person at the machine or through a mobile app. In order to enable efficient, centralized management of a large number of kiosks in the field, the machines must be IoT-enabled and connect through an elastic cloud infrastructure. Most importantly, all design objectives were undertaken with the USDA Food Safety Code in mind. ## The Solution: Smart, Automated Kiosk Deaton worked with JUKKA and other world class partners in industrial design, software development, back-end infrastructure, and user experience architecture to deliver the JUKKA vision. Given the high-end design sense and sophisticated use of smart technology, Deaton’s approach was to design this machine to industrial standards, with major components organized in a modular fashion. This would allow for ease of maintenance, technology upgrades and varying customer requirements. In 2017, Deaton completed a pre-alpha unit to prove the design of a 3-axis centralized robotic arm that would serve as the primary product conveyance throughout the machine. At the same time, Deaton engaged with several leading refrigeration companies to customize a refrigeration/freezing system that would allow JUKKA the ability to adjust storage temperature at will. This system met new regulations using a refrigerant that required specific safety and design concerns. Software design, UX architecture and back-end systems infrastructure were underway in preparation for the next phase. * * * By 2019, a functional alpha unit was completed and available to demonstrate JUKKA's vision to potential industry clients from CPG, retail, restaurant chains, etc. This alpha served everything from breakfast sandwiches to cinnamon rolls to barbeque brisket at or better than restaurant / manufacturer quality standards. All the while, Deaton continued to evolve the design to incorporate eID verification features (for example, age and/or identity-controlled items) and impending health safety considerations (e.g., COVID-19). By 2021 - during a global pandemic-Deaton delivered a functional beta unit, ready to deploy in a consumer field test for JUKKA's strategic partner, a global contract foodservice company. They chose an essential business-a large semiconductor facility in Austin, TX-to serve as the primary source of a hot meal for hundreds of swing shift employees. This unit included timely health safety features, such anti-microbial coated touch screens and UV sanitation for high-touch areas. Due to COVID-19, it was important for this field test to be monitored by JUKKA and Deaton teams. Taking advantage of this situation, JUKKA and Deaton proceeded with active mechanical and software engineering updates throughout the field test.Because of these aggressive, continuous improvement efforts, Deaton has well-positioned JUKKA for the next phase: Design for Manufacturing (DFM) with the OEM of choice. Engineering Highlights: - Multi-axis robotic conveyance to move the product between refrigeration, heating, and dispensing/presenting positions - Microwave customization to allow ingress/egress. Product reheating settings by product, and sanitization - Additional customer-interactive features such as: facial recognition cameras, integrated microphones and speakers, and customer-interface lighting - Multiple product verification features (bar code readers, product present sensors, etc.) - Machine controls integration with front and back-end systems - Integral displays with touch-screens for order entry and machine control - Unique modular frame to support high-end fascia, prevent tampering, and allow for ease of assembly and service/maintenance - Proprietary product packaging design - Full concept ideation to detailed design, test, and build - Payment hardware and third-party processor certification Two Sierra Way (512)981-6830 #### Case study # TLA-Bale Tech-Design and Build a Portable Waste Baling System ### The Client: TLA-Bale Tech, LLC a subsidiary of Transload America, Inc. TLA-Bale Tech, LLC is a subsidiary of Transload America, Inc. TransLoad was formed in 2002 to own and operate businesses associated with rail-based transportation, handling, recycling and disposal of waste material. The Company's strategy is to satisfy and exploit an increasing need for economical long-haul transportation and disposal of solid waste from large urban centers in the US and Canada where capacity is becoming increasingly limited, to disposal facilities in the Midwest and Southeast where disposal capacity is more abundant and economical. ## The Challenge: Design and Build a Portable Waste Baling System TLA-Bale Tech hired Deaton Engineering, Inc. to design, engineer and produce manufacturing documentation for a portable and robust stretch-wrap baling system. The system needs to be suitable for continuous processing and be portable for standby solutions for unexpected waste management disruptions including: natural disasters, military zones, and economic hardships. The client wants to leverage decades of baling systems and waste management experience to pave the way for the development of portable processing equipment to handle municipal solid waste that is environmentally friendly, operationally efficient, and cost-effective. ## The Solution: Next Generation Bale Tech III Deaton Engineering, along with TLA-Bale Tech, produced the next generation stretch-wrap portable baling system that innovates the handling and delivery of waste commodities. Bale Tech III is a patented high-speed baling and wrapping system that produces highly compacted cylindrical bales of shredded waste. Bale Tech III bales have a standardized weight of 3 tons, when baling municipal solid waste and do not leak or emit odors, making them ideal for long-term storage and multi-modal transportation. * * * # Engineering Highlights: = Patented stretch-wrap baling technolog$ = Fully automated seamless processing system with remote diagnostic and performance data collectio6 = Portable, safe and simple to install with less than one day set-up tim4 = Creates hermetically sealed high-density cylindrically shaped bale\* = Bale weight 5,600 - 9,400 lbs with a density of 1,400 - 1,700 lbs per cubic yar2 = Length 50" - 60" and diameter 66" - 74≥ = Cycle time one bale per 80 - 130 seconds; approximately 120 tons/hour ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Product Development & Design Engineering ## Market Driven Product Development from Concept to Manufacture As product life cycles continue to get shorter, the need for new product innovation is relentless. If you miss opportunities to bring innovative solutions to market, your company can quickly become irrelevant. Innovation is no longer an option for growth, but a requirement for survival. And sadly, studies now suggest nearly half of the resources companies devote to the development of new products are spent on products that ultimately fail. Deaton Engineering can help you develop a strategic plan for product and technology investment decisions based on your needs. We follow a phase-based approach to product development and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and [manufacturing](https://www.deatonengineering.com/industries/lowvolumemanufacturing.php) preparation. We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. ![Complex Machine Design](https://www.deatonengineering.com/images/product-life-cycle.png) Deaton Engineering applies a dynamic design process that allows us to collaborate with you to create profitable, high-quality products quickly and efficiently. We provide turnkey product development from concept through manufacture. ## Optimizing Designs for Manufacturability & Reliability ### Product Innovation and Product Definition At the onset of a project, Deaton Engineering works with you to carefully define the goals, user requirements, and functional specifications. We examine how the product will be used, the quantities needed, how and where the product will be manufactured, and which certifications and classifications are required. ### Feasibility and Cost Analysis After the product is defined, material options, manufacturing techniques, and locations are evaluated. We assess how the product can be designed within a specified budget and manufactured at a target price. ### Product Design and Optimization Our unique process of concurrent, multidisciplinary innovation is tailored to meet your design and [manufacturing](https://www.deatonengineering.com/industries/lowvolumemanufacturing.php) development needs. Off-the-shelf components are integrated when appropriate in order to optimize cost and efficiency. When necessary, we also employ high-end tools such as [Finite Element Analysis](https://www.deatonengineering.com/services/elementanalysis.php) and parametric modeling to optimize the design. ## Product Development and Design Engineering Services - SolidWorks & ProE - 3d and parametric design - Computer aided design (CAD) - Solid modeling - Mechanical design - Electrical & electronic design - Portable electronics - Military products - Appliance design - Consumer product design - Product packaging - Product engineering - Digital prototyping - Rapid prototyping - Marketing & functional prototypes - Rugged design - Human factors design - User interface design - Plastic & metal design - User centered design - Design for shock & vibration - User requirements & functional specifications - Concept development - Industrial design - Design for usability & user experience - Design for quality - Design for manufacture (DFM) - Design for UL & CE standards - Enclosure design - Electronics packaging - Design for validation - [Design optimization, (FEA)](https://www.deatonengineering.com/services/elementanalysis.php) - [Medical device design](https://www.deatonengineering.com/industries/medicaldevices.php) - [Contract manufacturing services](https://www.deatonengineering.com/services/productdevelopment.php#) - [Engineering services list](https://www.deatonengineering.com/services/productdevelopment.php#) - [Product development experience](https://www.deatonengineering.com/services/productdevelopment.php#) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/productdevelopment.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/productdevelopment.php#carouselExampleIndicators) #### FAQs: What product development services does Deaton Engineering offer in Texas? Deaton Engineering provides comprehensive product development services, including: - Concept Development: Transforming ideas into feasible product concepts. - Design Engineering: Creating detailed designs that meet functional requirements. - Prototyping: Developing prototypes to validate designs and functionalities. - Testing and Validation: Ensuring products meet quality and regulatory standards. How does Deaton Engineering support Texas-based startups and established companies in product development? Deaton Engineering collaborates with both startups and established companies in Texas to: - Accelerate Time-to-Market: Streamline the development process to bring products to market faster. - Enhance Product Quality: Implement rigorous testing to ensure high-quality outcomes. - Optimize Costs: Utilize efficient design and design for manufacturing techniques to reduce costs. Can Deaton Engineering assist with regulatory compliance for products developed in Texas? Yes, Deaton Engineering ensures that all products comply with relevant federal and Texas state regulations, facilitating smooth product launches within the state. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How can Texas businesses initiate a product development project with Deaton Engineering? Businesses can [contact Deaton Engineering her](https://www.deatonengineering.com/contact.php) [e](https://www.deatonengineering.com/services/productdevelopment.php) or visit their Georgetown, Texas headquarters, a suburb of Austin, to discuss product development needs. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### The World’s Smartest Vending Machine: # Deaton Engineering Helps Design & Build Automated Food Kiosk [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-jukka.pdf) ![Deaton Engineering Helps Jukka Design & Build Automated Food Kiosk](https://www.deatonengineering.com/images/header-case-jukka.jpg) ## The Client: JUKKA Inc. JUKKA was founded on the concept of offering an endless variety of foods to a broad consumer audience where and when convenient for their busy lives. With all the smart technology available, their mission was to harness this, in innovative ways, to accelerate brands and improve consumer experience with foods on the go. ![](https://www.deatonengineering.com/images/logo-jukka-temp.svg) ## The Challenge: Reimagining the Vending Machine In 2014, JUKKA approached Deaton Engineering to help bring this vision to life by designing a smart kiosk that can store, heat, and vend a variety of snacks, entrées and desserts. Equally important was form factor, which had to be elegant and unlike the vending machines of the past. Transactions were to be cashless and secure, and customers would have the option of ordering in-person at the machine or through a mobile app. In order to enable efficient, centralized management of a large number of kiosks in the field, the machines must be IoT-enabled and connect through an elastic cloud infrastructure. Most importantly, all design objectives were undertaken with the USDA Food Safety Code in mind. ## The Solution: Smart, Automated Kiosk Deaton worked with JUKKA and other world class partners in industrial design, software development, back-end infrastructure, and user experience architecture to deliver the JUKKA vision. Given the high-end design sense and sophisticated use of smart technology, Deaton’s approach was to design this machine to industrial standards, with major components organized in a modular fashion. This would allow for ease of maintenance, technology upgrades and varying customer requirements. ![](https://www.deatonengineering.com/images/jukka-double.jpg)In 2017, Deaton completed a pre-alpha unit to prove the design of a 3-axis centralized robotic arm that would serve as the primary product conveyance throughout the machine. At the same time, Deaton engaged with several leading refrigeration companies to customize a refrigeration/freezing system that would allow JUKKA the ability to adjust storage temperature at will. This system met new regulations using a refrigerant that required specific safety and design concerns. Software design, UX architecture and back-end systems infrastructure were underway in preparation for the next phase. By 2019, a functional alpha unit was completed and available to demonstrate JUKKA’s vision to potential industry clients from CPG, retail, restaurant chains, etc. This alpha served everything from breakfast sandwiches to cinnamon rolls to barbeque brisket at or better than restaurant / manufacturer quality standards. All the while, Deaton continued to evolve the design to incorporate eID verification features (for example, age and/or identity-controlled items) and impending health safety considerations (e.g., COVID-19). By 2021 – during a global pandemic – Deaton delivered a functional beta unit, ready to deploy in a consumer field test for JUKKA’s strategic partner, a global contract foodservice company. They chose an essential business – a large semiconductor facility in Austin, TX – to serve as the primary source of a hot meal for hundreds of swing shift employees. This unit included timely health safety features, such anti-microbial coated touch screens and UV sanitation for high-touch areas. Due to COVID-19, it was important for this field test to be monitored by JUKKA and Deaton teams. Taking advantage of this situation, JUKKA and Deaton proceeded with active mechanical and software engineering updates throughout the field test. Because of these aggressive, continuous improvement efforts, Deaton has well-positioned JUKKA for the next phase: Design for Manufacturing (DFM) with the OEM of choice. ## Engineering Highlights: - Full concept ideation to detailed design, test, and build - Multi-axis robotic conveyance to move the product between refrigeration, heating, and dispensing/presenting positions - Custom, automated refrigeration/freezing system to house multiple product types and dispense in the proper order, with customized software-switchable temperature control - Microwave customization to allow ingress/egress. Product reheating settings by product, and sanitization - Additional customer-interactive features such as: facial recognition cameras, integrated microphones and speakers, and customer-interface lighting - Integral displays with touch-screens for order entry and machine control - Proprietary product packaging design - Unique modular frame to support high-end fascia, prevent tampering, and allow for ease of assembly and service/maintenance - Machine controls integration with front and back-end systems - Payment hardware and third-party processor certification - Multiple product verification features (bar code readers, product present sensors, etc.) #### Manufacturing Streamline # Deaton Drives Efficiency for Honda Facility ### The Client: Honda Motor Co., Ltd. Tier 1 Supplier Honda manufactures a wide array of vehicles for a world of diverse needs and lifestyles. All Honda vehicles demonstrate their leadership with high performance, superior fuel economy, optimum safety, and driving pleasure. Honda's unique innovation has earned respect worldwide. That’s how they sell more than 3.5 million vehicles around the globe each year. ## The Challenge: Semi Automated Manufacturing Line for Mexico Our customer, a tier 1 supplier to Honda and other car manufacturers, needed to expand their manufacturing capacity in their Mexican facility. The challenge, design and fabricate a semi-automated manufacturing line to assemble and test airbag horn assemblies at a rate of 1 every 29 seconds. The new design had to be flexible enough to handle 19 product variations, reduce product change over time and meet strict Automotive TS 16949:2002 standards for quality and record keeping. ## The Solution: Manufacturing Line Capable of Running 19 Product Variations Deaton Engineering designed a manufacturing line that integrated quality assurance and test. We incorporated a poka- yoke design to eliminate left hand or right hand part substitution errors. The human-machine interfaces (HMIs) provided assembly instructions in the operator's language and controlled all machine operations. We were able to automate the manufacturing process and critical testing while taking advantage of low cost labor to move subassemblies from station to station. The time required to change over a line was greatly reduced by having the machines pre-configured according to bar coded part numbers. * * * # Engineering Highlights: Product change over was reduced from 6 hours to less than 2 hour 11 stations including: electrical testing, ultrasonic welding, mechanical testing and final packout Bar code part & subassembly management over a secure wireless network, records retained for 30 years Parts are locked down if test detects failure-only authorized personnel can release part Universal design capable of handling 19 product variations Additional manufacturing lines were designed for Brazilian facility. #### Case study # Validation of New Pharmaceutical APCS # is in the Bag ### The Need: Part 11 Compliant Validation of an Automated Process Control System Pharmaceutical companies must validate quality-affecting computerized systems in accordance with the FDA's ruling under 21 CFR Part 11. The high level of process control required for Good Manufacturing Practice compliance makes Automated Process Control Systems (APCS) one of the most critical applications of this requirement. Deaton Engineering performs validation services for computer systems and manufacturing equipment, and our work has repeatedly stood up to the scrutiny of FDA auditors. This case study was performed for a major pharmaceutical manufacturer headquartered in the US that specializes in the manufacture of sterile products. ## The Challenge: Validate the Automated Process Control System of a New Autofiller System Validate the automated process control system (APCS) of a high-volume packaging machine designed to form, fill, and seal bags containing a drug product solution. The APCS consisted of five Human-Machine Interfaces (HMIs), three Programmable Logic Controllers (PLCs), and an array of sensors to control the process. The machine was a new design for the customer, acquired to meet the production demands of a new product line. If successful, it would eliminate the need for three other processes used to produce similar products. The project presented a number of challenges. There was very little experience with the machine, so the technology would have to be fully reviewed and understood. In addition, the entire validation would have to be completed under a tight deadline for inclusion in a new drug application (NDA) filing. ## The Solution: Validation Ready for FDA Review Deaton Engineering quickly developed a validation plan to identify the scope, responsibilities, strategy, and technical challenges for the project using our total quality approach to validation. Our engineering experts were able to review the entire system to assess potential risks and identify technical hurdles that might be encountered. Deaton Engineering worked with the customer to create a functional specification for the control system, a documented risk assessment to analyze potential hazards and existing mitigations, a design specification for the entire machine, and installation and operational qualification protocols. * * * Each validation experiment was executed with minimal impact on client production. A validation report-prepared in accordance with the FDA's expectations for current Good Manufacturing Practices - was submitted to the customer detailing each experiment, its results and conclusions. # Engineering Highlights: E Provided the professional knowledge base necessary to conduct a thorough risk assessment on a new technolog/ E Delivered validation services that have been proven to meet the FDA's expectations for GMP manufacturers% E Report was reviewed in its entirety by the FDA without inquiries or comments% E Project completed and report deliveredD E in time for NDA submission. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Test Engineering, Quality Assurance & Quality Control ## Automated Test Solutions to Guarantee Product Quality and Reduce Manufacturing Risks Global competition, customer demands, and various regulatory bodies have put more emphasis on quality control and quality assurance. Quality has become a key product differentiator and a manufacturing necessity by providing plant managers with the information they need to make strategic decisions. If your company requires fast, easy access to data for insights into operational processes, Deaton Engineering can help. We will team with you to design, build, and implement robust, continuous online quality verification systems. We also design custom test equipment and develop test plans to ensure quality. ![Test Engineering, Quality Assurance & Quality Control](https://www.deatonengineering.com/images/header-test-eng.jpg) ## Custom Test and Quality Assurance for Improved Process & Manufacturing Robustness, and Reliability ### Fully Automated System Testers Deaton Engineering designs and builds semi- and fully [automated test systems](https://www.deatonengineering.com/services/automation.php) to meet your test specification criteria. DE can develop test systems using any development platform. ### Integrated Quality Assurance & Quality Control Systems Deaton Engineering teams with you to integrate quality control systems that ensure product quality and cost efficiency. We design real-time quality verification systems that meet security demands and government regulations. Our integrated solutions help your company respond to business initiatives throughout the plant. ### Custom Test Fixtures Deaton Engineering designs and builds custom test fixtures that reduce labor costs and make final assembly more efficient. Our engineers provide innovative solutions to automate, simplify, and improve your current manufacturing processes. ## Test Engineering, Quality Assurance & Quality Control Services - Quality assurance (QA) - Quality control (QC) - Quality management - Electrical and squib test - Data acquisition - Machine vision - Inspection equipment - Mechanical test - Automated test equipment (ATE) - Test automation & controls - Test engineering - Manufacturing quality control - Pharmaceutical quality control - Custom test equipment - Quality assurance testing - Functional tester - Test plan development - Functional testers - Automated system testers - Custom test fixtures - Integrated test systems - Integrated quality control systems - Motion system controls - Factory acceptance testing (FAT) - Failure modes & effects analysis (FMEA) - Design of experiments (DOE) - Gage repeatability and reproducibility (R&R) - Statistical process control (SPC) - [Software engineering & process control](https://www.deatonengineering.com/services/softwareengineering.php) - [Engineering services](https://www.deatonengineering.com/services/customtest.php#) - [Machine design, mechanical & electrical engineering](https://www.deatonengineering.com/services/machineequipment.php) - [Process and manufacturing equipment list](https://www.deatonengineering.com/services/customtest.php#) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/customtest.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/customtest.php#carouselExampleIndicators) #### FAQs: What custom test systems does Deaton Engineering offer in Texas? Deaton Engineering designs and builds custom test systems tailored to specific client requirements. These systems integrate advanced technologies and methodologies to ensure product quality, compliance, and performance. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How do custom test systems benefit Texas manufacturers? Custom test systems help Texas manufacturers by: - Ensuring Quality: Verifying that products meet specified standards and function correctly. - Enhancing Efficiency: Streamlining testing processes to reduce time and labor costs. - Facilitating Compliance: Ensuring adherence to industry regulations and standards. Can Deaton Engineering integrate custom test systems into existing Texas facilities? Yes, Deaton Engineering designs test systems that can be seamlessly integrated into existing manufacturing setups, minimizing disruptions and ensuring compatibility. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How can Texas businesses engage Deaton Engineering for custom test system projects? Businesses can [contact Deaton Engineering here](https://www.deatonengineering.com/contact.php) or by visiting their Georgetown, Texas headquarters, a suburb of Austin, to discuss custom test system needs. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Complex Machine Design Do you need to design a complex mega machine or industrial equipment that doesn’t exist? No problem for DE. We’ve been designing and building complex machines for 30 years. Need to redesign existing equipment? We do that too. If it’s never been done before, that’s our sweet spot. If you’re looking for a commodity piece of equipment, we’re not your engineering firm. ![Complex Machine Design](https://www.deatonengineering.com//images/header-complex-mach-des.jpg) ## Some Examples of our work: ![Card image cap](https://www.deatonengineering.com//images/sv-card.jpg) ##### iFLY Largest vertical wind tunnel in the world, 80-foot-tall mega machine, 4 turbo prop fans generating 1 mega-watt of power. One of the largest SolidWorks parametric designs ever attempted. [Case Study](https://www.deatonengineering.com/case_studies/ifly.php) ![Card image cap](https://www.deatonengineering.com//images/baletech-card.jpg) ##### TLA–Bale Tech Design a patented high-speed baling and wrapping system that produces highly compacted cylindrical bales of shredded waste. Creates hermetically sealed high-density cylindrically shaped bales. Bale weight 5,600 - 9,400 lbs. with a density of 1,400 - 1,700 lbs. per cubic yard. Length 50" - 60" and diameter 66" - 74". Cycle time one bale per 80 - 130 seconds; approximately 120 tons/hour. [Case Study](https://www.deatonengineering.com/case_studies/bale_tech.php) ![Card image cap](https://www.deatonengineering.com//images/briggo-card.jpg) ##### Briggo Design & build automated coffee kiosk. The machine replicates the technique used by elite baristas while adding the precision and repeatability that comes with robotics. The standalone coffee kiosk, combines premium coffee ingredients, precise robotic technology, and a mobile ordering platform to deliver coffee exactly how and when the customer likes it. [Case Study](https://www.deatonengineering.com/case_studies/briggo.php) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com//services/complex-machine-design.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com//services/complex-machine-design.php#carouselExampleIndicators) #### FAQs: What complex machine design services does Deaton Engineering offer in Texas? Deaton Engineering specializes in designing and building complex machinery, including: - Custom Industrial Equipment: Developing machines tailored to specific operational requirements. - Redesign of Existing Equipment: Enhancing performance and efficiency of current machinery. - Turnkey Solutions: Providing end-to-end services from concept through manufacturing. Can Deaton Engineering handle projects that have never been done before? Absolutely. Deaton Engineering thrives on innovative challenges, making them ideal for projects lacking off-the-shelf solutions. What are some examples of Deaton Engineering's complex machine design projects in Texas? Notable projects include: - iFLY: Designing the world's largest vertical wind tunnel, an 80-foot-tall structure powered by four turbo prop fans generating 1 megawatt of power. - TLA–Bale Tech: Creating a patented high-speed baling and wrapping system producing hermetically sealed, high-density cylindrical bales of shredded waste. - Briggo: Developing an automated coffee kiosk replicating elite barista techniques with robotic precision. How does Deaton Engineering approach complex machine design projects? Their process includes: - Discovery: Understanding client challenges and goals. - Solution Assessment: Determine if off-the-shelf solutions exist; if not, proceed with custom design. - Economic Evaluation: Assessing the value and impact of solving the problem. - Scope Definition: Collaboratively defining the problem and project scope. - Phased Design Approach: Following a structured process from conceptualization to manufacturing. How can Texas companies start a complex machine design project with Deaton Engineering? Companies can initiate projects by [contacting Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visiting their Georgetown, Texas, a suburb of Austin, office for consultations.  Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Automated Cups of Perfection: # Deaton Engineers Help Briggo Design & Build Automated Coffee Kiosk [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-briggo.pdf) ![Deaton Engineers Help Briggo Design & Build Automated Coffee Kiosk](https://www.deatonengineering.com/images/header-case-briggo.jpg) ## The Client: Briggo, Inc. Briggo, Inc. is focused on brewing your personalized, perfect cup of coffee, every time. Founded in 2008 in Austin, TX, Briggo is a standalone coffee kiosk, combining premium coffee ingredients, precise robotic technology, and a mobile ordering platform to deliver coffee exactly how and when you like it. Briggo’s goal is to install kiosks in locations where the need for quality coffee is unfulfilled by traditional coffee shops. ![](https://www.deatonengineering.com/images/logo_briggo.png) ## The Challenge: Design and Build an Automated Coffee Kiosk. In 2009, Briggo approached Deaton Engineering (DE) to transform their vision into a functioning prototype. Each subsequent version of the machine would need to become more complex, starting with a primitive lab unit, progressing to a semi-automated kiosk installed at a commercial location, finally to a fully-automated kiosk. Briggo wanted to replicate the technique used by elite baristas while adding the precision and repeatability that comes with robotics. The machines also had to interact seamlessly with industrial design, middleware and mobile applications that Briggo simultaneously developed during DE’s design phase. ## The Solution: Semi- and Fully-Automated First Article Kiosks ![](https://www.deatonengineering.com/images/photo_briggo2.jpg) DE completed work on a functioning lab unit in 2010, and then a semi-automated kiosk was completed and installed at the Flawn Academic Center at the University of Texas in 2011. A Briggo employee attended the kiosk in order to place/retrieve cups and press start, but the kiosk did the rest, utilizing rotary and linear actuators, valves, sensors and custom software. The kiosk created a wide menu of drinks, including brewed coffee, espressos and lattes along with the standard array of additives. The kiosk stayed in use until the fully-automated Briggo Coffee Haus replaced it in 2013. DE worked with Briggo and other partners to create this new coffee experience that no longer required an attendant. The Coffee Haus provided more drink and additive options while significantly reducing the kiosk’s footprint. The Coffee Haus offered significant design upgrades with more motion control, parallel processing, and a modular design. After the installation of the Coffee Haus, DE assisted Briggo with the transition of further design & maintenance over to their in-house team. ## Engineering Highlights: - Multi-axis motion control - Precise motion profiles - Middleware and mobile application interaction - Control system design - Signal conditioning - Data acquisition - Software development - Safety standards compliance – food & beverage, electrical, fire ![](https://www.deatonengineering.com/images/photo_briggo1.jpg) Process Engineering, Facilities Engineering, and Process & Plant Safety Management The Evolution of Process and Facility Engineering Lower margins, rapid change, and limited resources make it difficult to keep pace with increasingly complex process requirements. Deaton Engineering can help you stay focused on your core competencies by managing and implementing process and facility changes for you. Our experts can apply the latest technology to help you gain strategic advantage through automation and optimization of your manufacturing processes. Deaton Engineering specializes in developing and integrating equipment to control and improve critical processes. We work in a variety of industries including food & beverage, pharmaceutical, medical device, semiconductors, and general manufacturing. We design systems that provide plant managers with real- time access to their manufacturing process data. Providing Operational Excellence, Risk Management, and Quality by Design to Speed up Manufacturing Process Development, Improve Product Quality, and Drive Down the Cost of Goods Sold Facility Engineering & Design Our mechanical, electrical, and software engineers work with a wide variety of facility, process, and control systems. We can provide equipment and utility layouts as Our mechanical, electrical, and software engineers work with a wide variety of facility, process, and control systems. We can provide equipment and utility layouts as well as perform material flow analyses. From concept through commissioning, we provide design solutions that assure process integrity, operational efficiency, and regulatory compliance. We take the time to fully understand your facility, process, and software control needs. Our engineers design processes and systems that meet regulatory requirements set forth by the FDA, USDA, EPA, and others. Our designs can incorporate sanitary piping, purified water, water-for-injection, clean-in-place, and many other system requirements. Process tools such as in-line analysis, production and recipe management, asset utilization, process safety, and material tracking can provide a high level of control and efficiency. Validation and Compliance Engineering Our engineers provide turnkey validation services that cover the entire validation process. We develop and execute qualification protocols for equipment facility Our engineers provide turnkey validation services that cover the entire validation process. We develop and execute qualification protocols for equipment facility systems, and processes. Our documentation packages are extremely thorough and comply with regulatory requirement. Deaton Engineering can perform validations of automated control systems in accordance with 21 CFR 11. Machine Design & Automation Engineering Deaton Engineering designs fully automated systems and can incorporate industrial robots, vision systems, automated process control systems, and in-line monitoring. Process, Facilities, & Safety Engineering Services FDA, GMP, cGMP compliance & design Current good manufacturing practice (cGMP) GMP) Quality assurance & quality control Process & facility optimization Process automation & control Rugged and modular design Process automation & control Rugged and modular design Powder & bulk solids Quality by design Process analysis technology (PAT) FDA, GMP, cGMP compliance & design Current good manufacturing practice (cGMP) GMP) Current good manufacturing practice (cGMP) GMP) Quality assurance & quality control USP purified water, water for injection (WFI) Process & facility optimization Process automation & control Contamination control Electrical area classification Aseptic process & equipment design Plant engineering USP purified water, water for injection (WFI) Design of experiments Design of experiments Aseptic process & equipment design Powder & bulk solids Process development & design Quality by design Statistical process control (SPC) Ergonomics, safety equipment & machine guarding Start up and commissioning Statistical process control (SPC) Electrical area classification Industrial microwave systems Sanitary & clean process design Sanitary & clean process design Process safety and risk management Sanitary & clean process design Process safety and risk management Hazard analysis (HAZOP) Bulk flow Facilities services list Process engineering services list Process engineering services list Process and manufacturing equipment list Process and manufacturing equipment list Engineering services list Engineering services list Validation engineering services list Validation engineering services list FDA, regulatory and safety services list FDA, regulatory and safety services list ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ![](https://www.deatonengineering.com/images/build_thumb.jpg)[About Deaton](https://www.deatonengineering.com/about/index.php) ![](https://www.deatonengineering.com/images/partner_icon.jpg)[Partners](https://www.deatonengineering.com/about/partners.php) # About Deaton Engineering Deaton Engineering, Inc., is a full-service engineering company based in Georgetown, Texas. Established in 1991, Deaton Engineering offers a wide variety of engineering solutions and consulting services to clients in technology and process industries. Composed of a diverse group of Texas-licensed Professional Engineers, engineers, designers, and technical staff, Deaton Engineering provides services to support many fields of industry. ![](https://www.deatonengineering.com/images/deaton_building.jpg) We enable our clients to expand and supplement their own in-house engineering capabilities without hiring additional staff or purchasing expensive equipment. Deaton Engineering tailors engineering solutions for each client, using the optimal level of resources and skills required. Our talented and diverse experience pool allows us to be very creative and productive. DE is committed to ensuring the security and safety of our clients' data and intellectual property. We work with our clients under strict confidentiality agreements. Our staff has many years of experience working in widely varied industries. If you have an engineering problem, we can solve it. Visit our Services page to learn what we can do for your company. If you want more information about how DE works, [contact us](https://www.deatonengineering.com/contact.php "contact us"). ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) [![](https://www.deatonengineering.com/images/icn_pdf.gif)](https://www.deatonengineering.com/pdfs/industries/foodbeverage.pdf "Download PDF") # Food, Beverage, and Dairy – Engineering & Automation ## Engineered Solutions for Food, Beverage and Dairy Production Food and beverage products have become more complex and expensive to produce while globalization and regulatory requirements continue to limit margins. To remain competitive, companies must find innovative ways to produce their products faster, at lower cost, and with minimal waste. Not long ago, a capable maintenance group could design and maintain your process well enough to meet demand. New requirements and technology have made this model expensive at best. Today’s competitive environment requires a shift in design, selection, and deployment of process automation solutions. Deaton Engineering can help in this transition. Our engineering services take you beyond the “trial and error” approach to addressing the source of production and process issues. We design, build, and manage projects — from a single piece of equipment to a major plant expansion. ## Meeting Regulatory Expectations regarding Product Safety, Quality, and Production ### Compliance Engineering (FDA, 3-A, USDA, & NSF) Deaton Engineering’s mechanical, electrical, and software engineers are experienced with food and beverage regulatory requirements (FDA, USDA, NSF, and EFSA) and process requirements (sanitary piping systems and clean-in-place systems). By evaluating your [facilities and process systems](https://www.deatonengineering.com/services/facilitiesprocess.php), we can make recommendations for improvements in production management, recipe management, asset utilization, safety, and monitoring systems to help you evolve your process. ### Process and Facility Engineering & Safety Deaton Engineering can help you apply a risk-based approach to [regulatory compliance](https://www.deatonengineering.com/services/validation.php), thereby containing costs and seizing new opportunities. At any point in the production cycle, Deaton Engineering can lead the compliance process by developing and executing strategies that satisfy federal regulations. Our experts will verify the system was installed correctly and functions as designed. ### Manufacturing & Process Automation and Machine Design Deaton Engineering designs [fully automated systems](https://www.deatonengineering.com/services/automation.php) and can incorporate [industrial robots](https://www.deatonengineering.com/services/automation.php), [automated process control systems](https://www.deatonengineering.com/services/softwareengineering.php), and in-line monitoring. We integrate off-the-shelf equipment into our designs to [build equipment](https://www.deatonengineering.com/services/machineequipment.php) that evolves with your needs. We are experts at developing systems for in-line testing, security, and [quality control](https://www.deatonengineering.com/services/customtest.php). All of our equipment and processes are designed for quality. ## Engineering & Design Services - Clean in place systems (CIP) - Steam in place systems (SIP) - Sterilization in place systems - Pasteurization and sterilization processes - Food, beverage, & dairy processing - Food, beverage, & dairy packaging - Food, beverage, & dairy manufacturing - Material handling systems - Plant operations - Food engineering - Cross contamination - Product handling and conveying equipment - Ice cream and water ice extrusion nozzle design & fabrication - Ergonomics, safety equipment & machine guarding - Retrofitting manufacturing equipment & lines - Industrial microwave systems - Sanitary, clean equipment design - 3-A, FDA, USDA and NSF standards - Process & utility piping - Plant & site layout - Process safety and risk management - Hazardous area classification - Factory acceptance testing (FAT) - Industrial robots - [Process and manufacturing equipment list](https://www.deatonengineering.com/industries/foodbeverage.php#) - [Engineering services list](https://www.deatonengineering.com/industries/foodbeverage.php#) - [Process engineering services list](https://www.deatonengineering.com/industries/foodbeverage.php#) - [Facilities engineering services list](https://www.deatonengineering.com/industries/foodbeverage.php#) - [Validation engineering services list](https://www.deatonengineering.com/industries/foodbeverage.php#) #### FAQs: What services does Deaton Engineering offer to the Food, Beverage, and Dairy industries in Texas? Deaton Engineering provides comprehensive engineering solutions tailored to the Food, Beverage, and Dairy sectors, including: - Compliance Engineering: Ensuring adherence to regulatory requirements such as FDA, USDA, NSF, and EFSA standards. - Process and Facility Engineering: Evaluating facilities and process systems to recommend improvements in production management, recipe management, asset utilization, safety, and monitoring systems. - Manufacturing & Process Automation: Designing fully automated systems incorporating industrial robots, automated process control systems, and in-line monitoring to enhance efficiency and quality. How does Deaton Engineering ensure compliance with Texas-specific food and beverage regulations? Deaton Engineering's team is well-versed in both federal and Texas state regulations governing food and beverage production. They ensure all projects comply with guidelines set forth by the Texas Department of State Health Services (DSHS), including adherence to state-specific statutes and federal laws adopted by reference. Can Deaton Engineering assist with facility optimization and safety in Texas-based food and beverage plants? Yes, Deaton Engineering offers support services for production and utility systems in FDA-approved facilities across Texas. Their engineers can design, improve, or support systems that run operations, including on-site construction management and start-up support, ensuring efficiency and safety standards compliance. How does Deaton Engineering approach process automation for Texas food and beverage companies? Deaton Engineering designs and builds individual equipment or complete manufacturing lines to automate and improve processes. They utilize GAMP-compliant designs to create turnkey solutions that are reliable, cost-effective, and suitable for GMP validation, catering to the specific needs of Texas food and beverage manufacturers. How can Texas food and beverage companies initiate a project with Deaton Engineering? Companies can contact Deaton Engineering through its website or by visiting its headquarters in Georgetown, Texas, a suburb of Austin, Texas. Deaton offers free consultations to discuss potential projects and provide estimates, facilitating collaboration with Texas-based food and beverage firms. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. #### On Time and Under Budget # Deaton Delivers the COW to the Classroom ### The Client: Ignite! Learning Ignite! is a company committed to helping teachers by creating reliable, effective, and fun educational media. The company's flagship product is the Curriculum On Wheels (COW), a flexible multimedia curriculum tool designed to deliver comprehensive science and social studies media content to students in a motivational and engaging way. School districts and public and private schools in Texas, South Carolina, Virginia, Georgia, Tennessee, Louisiana, Nevada and California have adopted the Ignite! Curriculum on Wheels to help improve student performance in science, social studies and history. ## The Challenge: Prototype & Build Ignite! came to Deaton Engineering with an urgent need to design and prototype their product concept and begin shipments in just six weeks. The device would be a self-contained unit featuring a built-in computer, LCD projector and speakers. The overriding requirement was that elementary and middle school teachers would be able to simply plug in the device and begin a lesson. ## The Challenge: Prototype & Build Ignite! came to Deaton Engineering with an urgent need to design and prototype their product concept and begin shipments in just six weeks. The device would be a self-contained unit featuring a built-in computer, LCD projector and speakers. The overriding requirement was that elementary and middle school teachers would be able to simply plug in the device and begin a lesson. * * * # Engineering Highlights: # Delivered the award-winning "Curriculum on Wheels" on time and on budge \# Developed manufacturing and quality assurance procedure \# Designed versions for US and International market \# Manufactured the first 1,000 unit \# Provided fulfillment services and drop shipped units worldwid \# Transitioned manufacture to lower cost domestic contract manufacturer # Machine Design, Mechanical Engineering & Electrical Engineering ## Machine & Equipment Designed to Meet Today's Global Standards Industry leaders hav e learned that to maintain a competitiv e adv antage in the global marketplace y ou must continually improv e y our operation. But ef f orts to implement change must be weighed against the constant pressure of lower margins, higher demand, and what seems to be a continually shrinking pool of resources. Deaton Engineering can help by integrating technology solutions while y ou stay f ocused on core competencies. We can ev en integrate production data directly into y our ERP sy stem to prov ide real-time analy sis capabilities. Well engineered solutions are a necessity to stay ahead of the ef f iciency curv e. The experts at Deaton Engineering can design, build, install, and v alidate custom equipment to help y our plant work smarter. We use of f -the-shelf equipment and open standards whenev er possible to create solutions that can ev olv e ov er time. We f ind the best solution to y our problem by not promoting component manuf acturers. Our products can be designed to meet global regulations and required certif ications including UL, CE, ANSI and others. We understand the impact of regulatory requirements and design equipment with v alidation and compliance in mind. ## Design, Simulate, Build, and Test ### Turnkey Machine Design and Build Deaton Engineering designs and builds custom equipment f or many industries f rom pharmaceutical to heav y machinery. We design turnkey machines, enclosures, electrical sy stems, mechanisms and process controls. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower y our cost of ownership by minimizing training, operator interv ention, downtime, and rev alidation. ### Customized Electrical Equipment & Electronics Certain solutions simply cannot be implemented using only of f -the-shelf equipment. Whether it is a straightf orward design inv olv ing signal conditioning or a more complex design inv olv ing f ull wireless data transmission, Deaton Engineering can prov ide complete design and build serv ices. Our electrical engineers design custom components including control panels, cable harnesses, electrical drawers, signal conditioning, AC/DC power distribution blocks, wireless dev ices, low-power embedded controllers, data acquisition units and machine saf ety circuits. Deaton Engineering uses the latest methodologies and design practices, allowing f or more ef f icient and low-maintenance designs. Our in-house PCB capabilities (schematic capture, lay out, procurement, assembly & test) cov er multi- lay er, high-speed, low/high power, and small f ootprint designs (i.e., BGA). This results in f inished products ranging f rom single-lay er interf ace boards to multi- lay er high-speed ARM-based microcontroller units; f rom large electromechanical relay boards to miniaturized wireless dev ices. ### Designed for Good Manufacturing Practices (GMP) & Validation To ensure our designs meet current GMP requirements, we f ollow the GAMP lif e cy cle model f or automated sy stems to f acilitate v alidation. We design and build indiv idual pieces of equipment or complete manuf acturing lines to automate and improv e the manuf acturing process. ## Machine Design, Mechanical Engineering & Electrical Engineering Services Mechanical engineering Cable & connector design Electrical engineering Electrical sy stem integration Power usage design & management Chassis, enclosure, and panel design Embedded sy stems Rugged & hardened design Machine design Sheet metal & plastic design Equipment design International standards; CE, UL, & RoHS Machine saf ety & machine guarding Parametric design Serv o & stepper motors Sof tware & controls sy stems Motion control, linear actuators Measurement & inspection sy stems OSHA & ANSI design PLC, HMI and computer control Machine v ision Industrial robots Electronic engineering Process and manuf acturing equipment list Electromechanical design Engineering serv ices list Industrial control Manuf acturing serv ices list Design f or quality & v alidation FDA, regulatory and saf ety serv ices list DEATON ENGINEERING YOUR VISION, OUR PRECISION You Have a Vision. And now you have a partner to help you realize it. We’re a full-service engineering company offering a wide variety of solutions and services to a broad range of industries since 1991. Our talented specialists with applied experience and an excellent command of the tools of the trade partner with you to engineer answers. Designed & built the award-winning Briggo Coffee Haus automated coffee kiosk that replicates techniques used by elite baristas with the precision and repeatability that comes with robotics. “From the earliest concept, Deaton’s team of dedicated engineers applied their broad range of skills and experience to create the world’s first autonomous robotic specialty coffee platform. This innovation ushered in a wave of autonomous food and beverage delivery systems currently in development around the world.” — C. Studor, Founder/CTO of Briggo, Inc., CTO of NowCuisine.com JUKKA — John Serieka, COO of JUKKA Inc. JUKKA Approached Deaton Engineering to help reimagine the vending machine. Together, we prototyped and field tested an innovative automated foodservice kiosk that can service hundreds of an innovative automated foodservice kiosk that can service hundreds of swing shift employees, with timely safety features. “Deaton Engineering has provided exceptional engineering services & intelligence to JUKKA Inc. since our founding 5 years ago. Our experience has been that Ed Deaton and his team of DEI engineers are amazingly qualified & technically proficient – but just as importantly they are tenacious problem solvers. DEI immediately embraced our project vision, and led the transformational design & technology of our automated robotic vending equipment that is now set to further evolve the foodservice industry …” Deaton Engineering, Inc. Two Sierra Way INDUSTRIES Medical Device Design Pharmaceutical Engineering Food, Beverage & Dairy Manufacturing SERVICES (512) 981-6830 CERTIFIED Electrical Engineering Machine Controls Complex Machine Design & Build Contract Manufacturing Services Finite Element Analysis Software Engineering Validation Engineering Test Engineering & QA/QC Automation Engineering & Robotics Product Development ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) # What Your Dreams of Flying _Really_ Mean #### It’s clear. Those dreams mean you need to visit the nearest iFly to simulate your own high-adventure skydiving. No experience necessary. [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-ifly.pdf) ![Deaton Manages Mega Design and Build for iFLY](https://www.deatonengineering.com/images/photo-header-ifly.jpg) ## The Client: iFLY, LLC iFly produces modern skydiving wind tunnels (both standard and custom) designed for the general public. You enjoy the completely immersive experience of skydiving without ever having to pack a parachute, pull a ripcord, or jump out of a perfectly good airplane. ![](https://www.deatonengineering.com/images/logo-ifly.svg) ## The Challenges Were Many: We Earned Our Wings Deaton helped take projects from the raw brainstorming and whiteboard stage… to collaborating with fabricators and suppliers for design of manufacturable and cost-effective components… _across nearly all 9 generations of iFly Tunnel Systems._ ##### Here are just some of the challenges we researched and helped iFly and its suppliers overcome: - Airflow sealing methods and solutions. - Integrated sound dampening and conditioning (chilled turning vanes provide “air conditioning”). - Assembly, lifting, and installation challenges. - Sealed joints within and sealed flexible joints between critical components. ## The Solution: Ideas Taking Flight _For 20 Years_ We at Deaton have had the pleasure of working with iFly for 20 years. We’ve been involved and relevant at every phase, whether working on their standard designs or providing services for many of their custom projects, _including the world’s largest wind tunnel and recirculating tunnels on cruise ships._ - _The Concept “What If?” Phase:_ Whiteboard sketches and brainstormed conceptual designs were circulated among a diverse team of fabricators, control system and structural engineers, architects, aerodynamicists and owner groups to conceptualize machines. - _Ideas Meeting Real-World Constraints:_ We worked with fabricators using best practices to design manufacturable and cost-effective components to match complex geometry of desired airflow, and modular design for loading into shipping containers for transport around the world. - _Getting Real and Realer:_ Used hand calculations, finite element analysis (FEA), and engineering judgement to optimize and validate designs. Developed methods to predict and evaluate component strengths, quantify internal/external loads and component responses. Created loading and interface documents for interfaces to, and loads imparted upon, building structure. - _Common Components, Standard Procedures, Documentation_ - Configurable components used in multiple product offerings. - Generated or revised standard fabrication and procedural documents. - Developed requirements, testing, and acceptance criteria for supplier coatings and finishes. - Developed specification documents for critical machine components. - Assisted with integration of product design management system. - _Installation and Assembly:_ Worked with installers to improve processes on standard offerings. Worked with fabricators to improve component designs and perform cost analyses and comparisons. Created manufacturing drawings and sequenced assembly instructions to ensure the machines can be assembled. How Deaton Engineering and MLC designed and built the world's largest indoor wind tunnel - YouTube Tap to unmute 1x [How Deaton Engineering and MLC designed and built the world's largest indoor wind tunnel](https://www.youtube.com/watch?v=rdHfEcISsHg) [Deaton Engineering](https://www.youtube.com/channel/UCZXmWma7vUQz_5oHQTwH-JQ) Deaton Engineering30 subscribers ## Engineering Highlights: [THE LARGEST WIND TUNNEL IN THE WORLD](https://iflysales.com/custom-tunnels/) Designing the largest wind tunnel in the world comes with special challenges and considerations. - 32 foot in diameter and 104 foot heigh in the flight chamber. - A machine that dwarfs all other designs, including a 10-story structure with 16 fans generating more than 7 mega-watts of power. - Huge parametric models in SolidWorks including thousands of unique components. Worked with aerodynamicists to develop multi-story machine components that met airflow requirements. Designed components with access for maintenance. - Load-bearing supports and tensioning methods integral to the airflow space, and fairings and bull-noses to smooth transitions and provide quality airflow. - Prepared documentation and participated in first-article approval and prototype/mock assembly of selected components. - Worked with structural engineers to provide machine loads for, and to accept loads imparted by, the structure. DE provided critical analysis and simulation of loads through machine components to support enormous wind load forces on an order of magnitude larger than previous designs. ![ifly wind tunnel outside view](https://www.deatonengineering.com/images/ifly-screen3.jpg) [A WIND TUNNEL ON A CRUISE SHIP](https://iflysales.com/custom-tunnels/) - Worked with challenging architectural and structural interfaces. - Developed solutions for critical geometry and weight-loading requirements with limited space availability. - Develop and implement new integrated component structure support features and methods. - Developed and implemented new orientations for legacy components in design and solved challenges associated. - Developed and implemented seals for component interfaces. - Developed and implemented accessibility features for maintenance. - Identified corrosion and safety issues and provided features and guidance for prevention. ![ifly wind tunnel on the Quantum of the Seas cruise ship](https://www.deatonengineering.com/images/ifly-screen2.jpg) ### CASE STUDY # Deaton Engineering Designs Athletic Shoe Insert to Enhance # Athletic and Rehabilitation Performance. ## The Client: MedHab, LLC & RPM MedHab develops wearable technology – insoles that measure and monitor various metrics, giving medical care prescribers the ability to customize rehabilitation protocols to meet patients’ needs. Marketed as StepRite®, the device can measure body weight, force, gait, and flexibility in lower extremities using embedded sensors. Utilizing the same technology, MedHab’s subsidiary RPM2 has developed a set of apps that, when paired with the athletic insoles, can measure an athlete’s bilateral equivalence, weight distribution and range of motion. Athletes whose legs are bilaterally in sync are faster, stronger, and perform better at a higher level. RPM2 is an official Training Footbed Partner for USA Triathlon. Founded in 2008 and based in Fort Worth, TX, MedHab is a privately held company. ## The Challenge: Design a small footprint smart shoe insole system. In 2010, MedHab approached Deaton Engineering (DEI) to develop a proof of concept system in order to verify the feasibility of such a rehabilitation device. The main challenge was implementing all the necessary sensors and communication devices into a package small enough not to hinder a patient or athlete’s performance during daily use. The athletic insole system needed to withstand the wear and tear present inside athletes’ and patients’ shoes, while providing a reliable Bluetooth connection to a nearby device in order to sample data at up to 100Hz from a set of force sensors, a 3-axis accelerometer, a 3-axis gyroscope, and a 3-axis magnetometer. ## The Solution: Miniaturized Smart Inserts & App From the initial proof of concept (which was the size of a shoe box and powered off of 9V batteries, paired with passive insoles connected via ribbon cables) evolved a fully wireless device utilizing the latest in lithium polymer power technology and inductive charging miniaturized to fit inside a shoe insert. DEI developed a hardware system utilizing the latest in: low-power management, induction charging, Bluetooth communication, multi- sensor packaging, onboard memory, and BGA technology. Each insole housed a set of four force sensors connected to a miniaturized multi- layer PCB, which contained the 9-axis accelerometer/gyro/magnetometer, Bluetooth antenna and transceiver, induction and power management circuit, on-board non-volatile memory, and low-power microcontroller. All of this packaged into a board no bigger than a stick of gum. DEI developed custom firmware that allowed the insoles to communicate wirelessly to mobile devices. DEI also developed the app backbone and APIs for Android and iOS devices, later used by RPM2 to create their own control apps. ## Engineering Highlights: - Fully encased miniaturized design able to fit into molded insole without external parts. - Low-Power design utilizing lithium polymer rechargeable battery. - Inductive charging capabilities for wireless battery charging. - Bluetooth communication capabilities between the insoles and Android/ iOS devices. - 9-axis Accel/Gyro/Magnetometer & active force sensor integration. - Microcontroller-based PCB design. - Firmware and App (Android/iOS) development. Deaton Engineering, Inc. [www.deatonengineering.com](http://www.deatonengineering.com/) Two Sierra Way [sales@deatonengineering.com](mailto:sales@deatonengineering.com) Georgetown, TX 78626 (512) 981-6830 ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Conceptual. Compliant. Cool. # Deaton Engineering designs and integrates automated processing equipment for novelty ice cream production. [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-ice_cream.pdf) ![3D Extrustion mold](https://www.deatonengineering.com/images/header-ice-cream.jpg) ## Ice Cream Novelty Products: Concept to Production Deaton Engineering turns 2D drawings of novelty cartoon characters into 3D designs suitable for extrusion and production. Product design and size are based on customer’s equipment capacity. - Stick slices - Slices - Sandwiches - Cups - Cones - Bars ![](https://www.deatonengineering.com/images/space-face.jpg) ## The Challenge: Design & Fabrication of Ice Cream and Water Ice Horizontal & Vertical Extruders and Nozzles Deaton Engineering designs and fabricates ice cream and water ice horizontal and vertical extruders and nozzles. Our extruders are designed using parametric models to ensure they meet delivery and production requirements, and work the first time. The extruders can be designed for both new and existing product lines. Deaton Engineering understands sanitary design and manufacturing. DE incorporates these principals into every extruder we design and fabricate. ## The Solution: Custom extrusion equipment built for the demands of commercial production and compliance ![ice-cream extrusion assembly](https://www.deatonengineering.com/images/king-kong-extrusion.jpg) ### Extruders & Nozzles - Horizontal & Vertical - Single-flavor single-output - Single-flavor multi-output - Multi-flavor multi-output - Complex multi-flavor - Log products ### Product Handling Equipment - Stick gripper modifications and redesign - Stickless pickup devices - Cone pickup devices ### Chocolate Coating & Enrobing - Custom or product specific coating and/or enrober modifications ### Other Components & Equipment - Wafer Dispensers - Nut & Candy Dispensers - Conveyors ## Machine Improvements: - PLC programming & design - Automation - Clean, sanitary re-design - Cooling & hardening tunnel modifications - Liquid nitrogen applications - Special application cutters - Electronic drive retrofit ## EPA Mandated Risk Management Plan and Program (RMP): - RMP for ammonia refrigeration systems ![](https://www.deatonengineering.com/images/ice-cream-vader.jpg) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Design and Build for Validation: # Deaton Engineering Measures Up for Good Manufacturing Practices [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-machine_build.pdf) ![Thin Film Gauging case study header](https://www.deatonengineering.com/images/header-thinfilm.jpg) ## The Need: Accurate Measurement of Thin Films Transdermal patches have become increasingly popular for the administration of various drugs. While convenient and effective, patches present several challenges to formulation. Timed release of the drug is a function of the patch's surface area and thickness so accurate measurement of these physical dimensions is critical. Recognizing this need, Deaton Engineering agreed to develop a laser measurement gauge capable of making highly accurate measurements of thin films. The gauge would be purchased by a contract formulator for in-process testing of manufactured films impregnated with a drug substance. ## The Challenge: Design a Film-Thickness Measurement Technique The gauge would need to perform continuous thickness measurements of thin film polymer extrusions in a GMP manufacturing environment. The tolerances for film thickness in this application were extremely narrow so innovative techniques would be required. Product not meeting these criteria would be physically marked as out-of-specification. The size of the film and high rate of production would require multiple measurements to be taken across the film and processed in real time. Since it would be used for drug product formulations, the machine would have to be designed for validation and the control system would have to meet 21 CFR Part 11 requirements. ## The Solution: A Validated, In-Line Gauge for Analysis of Film-Thickness Deaton Engineering began by developing specifications to define the function, operation, installation, and acceptance testing of the measurement gauge. A design employing 5 laser displacement sensor pairs controlled by a PC was developed and proven against an application test plan. From these specifications, a turn-key film thickness measurement system was constructed at Deaton Engineering. The measurement gauge was successfully integrated into the customer's process and calibrated by the engineering team. ![](https://www.deatonengineering.com/images/photo_film_2.png)![](https://www.deatonengineering.com/images/photo_film_1.png) Deaton Engineering's validation team was involved in creating the functional specification of the gauge to ensure that critical functions could be validated in accordance with GMP requirements once installed. A set of protocols were created to challenge the system and ensure it complied with the functional specification. Each validation experiment was successfully executed and the results presented in a report suitable for FDA audit review. ## Engineering Highlights: - Technique for making very accurate film thickness measurements successfully developed and proven - The design for validation facilitated a smooth and efficient validation process - including Part 11 compliance validation of the control system - Delivery of a turn-key in-line process measurement system ready for GMP application ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) # Deaton Engineering Case Studies: Proven Success Innovation is best measured by its impact. Our case studies highlight the real-world success of our partners, showcasing how Deaton Engineering transforms abstract concepts into functional, high-performance systems. From the world’s first automated specialty coffee kiosk to complex medical device manufacturing, explore how our collaborative approach and engineering rigor have solved critical problems and driven commercial success for our clients. [One-Page Overview](https://www.deatonengineering.com//pdfs/deaton-engineering.pdf "Download a Quick Data Sheet") ![Deaton Engineering Case Studies](https://www.deatonengineering.com/images/feature-casestudies.jpg) ## Case Studies ##### MedHab, LLC & RPM2 Deaton Engineering designs athletic shoe insert to enhance athletic and rehabilitation performance. [Learn More ❯](https://www.deatonengineering.com/case_studies/medhab.php) ##### Briggo, Inc. Deaton engineers help briggo design & build automated coffee kiosk. [Learn More ❯](https://www.deatonengineering.com/case_studies/briggo.php) ##### Bat Conservation International, Inc. Deaton Designs & builds ultrasonic deterrents to prevent bat fatalities at wind farms. [Learn More ❯](https://www.deatonengineering.com/case_studies/batcon.php) ##### JUKKA Inc. Deaton Engineering helps design & build automated food kiosk. [Learn More ❯](https://www.deatonengineering.com/case_studies/jukka.php) ##### TLA - Bale Tech, LLC Design and build a portable waste baling system. [Learn More ❯](https://www.deatonengineering.com/case_studies/bale_tech.php) ##### Ice Cream Novelty Products Design and integrate automated processing equipment for novelty ice cream production. [Learn More ❯](https://www.deatonengineering.com/case_studies/ice_cream.php) ##### Dell Defense Services Deaton Engineering Creates a Military Hardened Design for Dell & US Air Force. [Learn More ❯](https://www.deatonengineering.com/case_studies/tbmcs.php) ##### Honda Motor Co., Ltd. Tier 1 Supplier Design and fabricate a semi-automated manufacturing line to assemble and test airbag horn assemblies at a rate of 1 every 29 seconds. [Learn More ❯](https://www.deatonengineering.com/case_studies/ifly.php) ##### TMGCore Design, engineer, prototype, and create a DFM package for a high-density data center using _two-phase liquid immersion cooling technology_. [Learn More ❯](https://www.deatonengineering.com/case_studies/honda.php) ##### Ignite! Learning Design and prototype a self-contained educational media system on a tight timeline. [Learn More ❯](https://www.deatonengineering.com/case_studies/ignite.php) ##### Validation of Pharmaceutical APCS Validate the (APCS) of a high-volume packaging machine designed to form, fill, and seal bags containing a drug product solution. [Learn More ❯](https://www.deatonengineering.com/case_studies/apcs.php) ##### Dell Computer Inc. / Tyrex Group Design and build an automated computer fan tester that controls and tests up 450 fans at once. [Learn More ❯](https://www.deatonengineering.com/case_studies/fan_test.php) ##### Accurate Measurement of Thin Films Design a film-thickness measurement technique for pharmaceutical transdermal patches. [Learn More ❯](https://www.deatonengineering.com/case_studies/machine_build.php) ##### Case study # TMGCore and Deaton bring revolutionary improvements to # data center design and operation. ### The Client: TMGCore TMGcore collaborates with global industry experts to design, create, and commercialize the next generation of high-performance computing solutions. High-performance computing (HPC) used to be (back in the late 1990s and early 2000s) the exclusive domain of university-based and federally funded national laboratories. Think: Sprawling, old-school, expensive data centers that were anything but energy-efficient. Because of greater volumes of data (requiring sophisticated analytics), lower hardware costs, and the arrival of machine learning and AI, the opportunity and need for HPC has gone mainstream. It’s the best way for your business to keep up with ever-more-demanding customers. Because, let’s face it, we’re all in the data and analytics business now. Until recently, though, there’s been an open question: If the need for HPC is obvious—and it is—how do you get a new data center that fully addresses your requirements for, among other things, a smaller footprint plus lower capital and operational expenditures? ## The Challenge: Understand, Design, and Build the High-Density Data Center At Deaton, we’re comfortable going where nobody has gone before. And that’s what TMGCore invited us to do. We are thankful for such invitations. TMGcore hired us to design, engineer, build prototypes, and create a DFM package for a high-density data center using two-phase liquid immersion cooling technology. TMGCore’s OTTO platform had to deliver first-of-their-kind improvements so that companies could deploy infrastructure at unprecedented densities beyond the threshold of traditional air-cooled strategies. Companies (TMGCore clients) realize they need the business-transforming power of high-performance computing. And the words “reliable,” “scalable,” “affordable,” “automated,” “environmentally friendly,” “cost-efficient” have to be in the mix. #### Challenge accepted. Data center redefined. * * * The Solution: Doing What Hasn’t Been Done Before. And Doing It Like You’ve Done It Before c There’s No Substitute for Being First: OTTO is the first-of-its-kind, commercial-ready, enterprise-grade, two phase liquid immersion cooling platform9 c Density? Oh, Yeah This Is Dense: Our design supports extreme, high-density computing blades consuming up to 6,000 watts per blade9 c Efficiency Pushed to the Max: OTTO has high-power flux of 3,750 watts per square foot vs. 150-200 watts per square foot in a typical air-cooled data center9 c Fully Autonomous Operations: A marketer might call it “OTTO-Pilot.” But whatever you want to call it, OTTO supports lights-out, self-healing, hands-off operation that enables all aspects of the platform to be remotely administered and monitored9 c Robotic Process Automation: Including edge deployments in lights-out facilities9 c Centralized Management: The OTTO Manager console is a management interface that enables monitoring and administration of the entire platform9 c Advanced Robotics: Deaton’s design fully automates the swap-out of installed blades for new blades while the machine is running. Translation: Zero down time. Additionally, we created a process to minimize vapor loss during these hot-swaps9 c Process Controls: We developed and implemented process controls, including pressure, temperature, fluid level, relative humidity, and more9 c Proprietary Components: We worked with fluid experts to conceptualize, develop, and test a Vapor Recovery System that mitigates elevated pressure and minimizes vapor loss. The system implements a “pervaporative membrane” to allow egress of water vapor from the machine without allowing fluid vapor through. We could go on and on here, taking you even deeper into all that our collaboration with TMGCore has required or produced: customizable blades, finite element analysis, produced: customizable blades, finite element analysis, material compatibility, safety features, design for integration into a customer facility… and much more. We’re engineers. We love getting into the weeds. c The First in I ts Type – OTTO is a commercial ready, enterprise-grade, two-phase liquid immersion cooling platform9 c U nparalleled D ensities – D EI’s design supports extreme high-density computing blades consuming up to 6,000 watts ( 6 kW) per blade9 c Fully A utono m ous O perations - OTTO supports lights-out, self-healing, hands-off operation that allows all aspects of the platform to be administered and monitored remotely9 Engineering Highlights: c R obotic P rocess A uto m ation or remote & edge deployments in lights-out facilities9 c Centrali zed Manage m ent - The OTTO Manager console is a management interface that allows for the monitoring and administration of the entire OTTO platform. * * * Q Advanced Robotics – DEI’s design fully automates the replacement of installed blades inside the machine with new blades while the machine is running (hot-swapping), and with zero down time. In addition, Deaton created a process to minimize the vapor loss during hot-swapsY Q Process Controls – Process controls, including pressure, temperature, fluid level, relative humidity, and other controls have been developed and implemented by DEIY Q Proprietary Components – DEI worked with fluid experts to conceptualize, develop, and test a Vapor Recovery system that mitigates elevated pressure in the machine and minimizes fluid vapor loss. The system implements a “pervaporative membrane” to allow the egress of water vapor from the machine without allowing fluid vapor throughY Q Customizable Blades – DEI developed mechanical, electrical and worked with partners on communications architecture for the blade/machine interface, which allows customers to have the flexibility to use their custom-built blades in the machine. Collaborating with partners of TMG, DEI developed an immersed power supply blades providing compute powerY Q FEA: Engineers at DEI performed finite element analyses on critical machine components for verification of the design robustnessY Q Custom measures and off-the-shelf equipment were implemented to identify critical process faults and report to control systeS Q Fluid Choice – The machine can be filled and operated with several compatible fluidsY Q Material Compatibility – DEI conducted research and consulted with subject matter experts on the materials that would be compatible with the specialty fluids to avoid chemical reactions and/or physical changes or damages to the fluid, parts and componentsY Q Safety Features – DEI performed risk assessments to deliver design features that mitigate electrical, mechanical, and health safety issues related to operation of the machineY Q Redundancy – Deaton enhanced the reliability of the machine and minimize down time. Redundancy was implemented for most componentsY Q Design for Integration into Customer Facility – Deaton’s design supported different types of power, such as 415V and 480V, and different facility water supply linesY Q Design for Manufacturing and Assembly Support – Deaton worked with high volume manufacturing partners to prepare the machine design for volume manufacturingY Q Prototype Build, Testing, Debugging, Optimization: DEI built a full-size prototype and tested the machine at system, subassembly, and component levels. If any issues arose during the testing, DEI’s engineers debugged them, and optimized the performance to meet customer needsY Q HMI (Human Machine Interface) – In addition to autonomous control, as well as remote manual control, operators of the machine will be able to manually control at the machine via a user-friendly, large, high-resolution touch-screenY Q Documentation – developed documentation for testing, shipping readiness, installation, commissioning, user operation, maintenance, and many other critical documentsY Q Aesthetics – DEI worked with our customer and their partner to include customer’s vision of an aesthetic machineY Q Project Management and Communication – DEI diligently managed the project and created a strong effective communication with our customer, vendors, machine shops, and others. In addition to OTTO 120, the first immersion cooling product of TMGcore, DEI has assisted TMGcore # to develop several other machine lines with various capacities that met customer needs. #### Consistency. Quality. Efficiency # Deaton Engineering Helps Dell Quality Test 450 Cooling Fans # Simultaneously ### The Need: Part 11 Compliant Validation of an Automated Process Control System Pharmaceutical companies must validate quality-affecting computerized systems in accordance with the FDA's ruling under 21 CFR Part 11. The high level of process control required for Good Manufacturing Practice compliance makes Automated Process Control Systems (APCS) one of the most critical applications of this requirement. Deaton Engineering performs validation services for computer systems and manufacturing equipment, and our work has repeatedly stood up to the scrutiny of FDA auditors. This case study was performed for a major pharmaceutical manufacturer headquartered in the US that specializes in the manufacture of sterile products. ## The Challenge: Design and Build An Automated Computer Fan Tester Dell and TyRex engaged Deaton Engineering to develop an automated fixture capable of simultaneously controlling and testing up to 450 fans for use during qualification of new computer cooling fan models. The data acquisition and control system necessitated independent control and monitoring of fan speed and input power. Additionally, the controller was required to recognize and disable a failed fan during testing. Multiple fan sizes and blowers needed to be fixtured and connected to the test system; a common, flexible mounting fixture was required to accommodate fans from 50mm to 92mm in diameter capable of providing power and signal distribution to each fan. ## The Solution: Automated Fan Test Fixture Deaton Engineering developed designs for the fixture’s circuit boards, fan mounts, power management and cable assemblies. * * * These components were used to create the test device, which was integrated with a standard thermal test chamber. Performance testing included one week of continuous power cycling for all the fans at 70C. Parametric testing was performed at the end of the week, the fans were cycled through their range of speed, while monitoring the speed and power demand of each fan independently. This data was stored on the control computer and used to trend the performance of each of the fans in the test. This cycle of performance testing and parametric testing was repeated for 7 weeks. The first article was built, installed and verified to demonstrate the final product met the design specifications. The designs, drawings, and procedures for building and installing the device were transferred to Tyrex for use with Dell components. # Engineering Highlights: Q Worked with Dell reliability engineers to develop fan tester requirements and specification6 Q Designed custom test rack capable of handling signal and power requirements necessary to simultaneously control 450 multidimensional fan6 Q Created adjustable mounting bracket to accommodate multiple fan sizes/models without jeopardizing airflo8 Q Designed and developed power distribution which incorporated unique circuit protection, cable routing, and thermal consideration6 Q Assembled transfer documentation package for deployment to Asian manufacturers to meet client needs ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Automation Engineering & Robotics ## Design, Development, and Implementation of Advanced Automation Systems Manufacturing is not what it used to be. Competition in today’s global marketplace is intense, and domestic manufacturers must work harder than ever to succeed. Compounding these challenges are customers and retailers that are savvier than ever, demanding lower prices and faster delivery times. To be successful, manufacturers must seek new strategies for controlling operating costs. While some may abandon domestic facilities and ship their operations overseas, this approach is often fraught with challenges. An alternative approach is to improve the efficiency of your current manufacturing process — right here, right now — with automation. Deaton Engineering helps North American manufacturing companies dramatically improve the quality and efficiency of their operation through the use of automation, robotics, and other efficiency measures that are often more cost-effective and profitable than off-shoring. Through automation, we can optimize your capital and labor resources in production, inventory management, quality control, and warehousing. Not only will you become more efficient and cost competitive, but you’ll also maintain tighter control of the operation than with manufacturing overseas. ![Automation Engineering & Robotics](https://www.deatonengineering.com/images/header-automoation.jpg) ## Factory Automation, System Engineering, & Robotics ### High-end Factory, Equipment, & Process Automation Deaton Engineering designs fully automated control systems that incorporate industrial robots, vision systems, custom hardware, and quality control measurement techniques. ### Robotic Automation Services Deaton Engineering works with numerous robot manufacturers to implement automation systems encompassing all forms of robotics including: pick and place, Cartesian, SCARA, and 4 and 6 axis robots. Deaton Engineering integrates robots ideal for automating applications such as palletizing, machine tending, material handling, packaging, cutting, material removal, and welding. We can also provide testing services for existing robotic systems. ### Automated Test and Quality Assurance Bridging the automation-to-enterprise gap is about leveraging manufacturing data in enterprise decisions. Deaton Engineering designs semi- and fully- [automated test devices](https://www.deatonengineering.com/services/customtest.php) for manufacturing lines. We team with you to integrate quality control systems designed to continuously improve product quality and increase efficiency. ## Partner with Deaton Engineering for Support & Integration of: - Industrial robots 4 and 6 axis - Vision systems - Laser displacement measurement - Motion control systems - Material handling - Pick & place robots - Laser marking and processing - Bar code scanners - Non contact measurement - Indexing systems - Assembly machines - PLC and PC machine control - Servo & stepper motors - Material joining systems - Packaging systems - [Process and manufacturing equipment list](https://www.deatonengineering.com/services/automation.php#) - [Process engineering services list](https://www.deatonengineering.com/services/automation.php#) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/automation.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/automation.php#carouselExampleIndicators) #### FAQs: What automation engineering and robotics services does Deaton Engineering offer in Texas? Deaton Engineering offers a range of services, including: - Factory Automation: Designing fully automated manufacturing and assembly systems that incorporate industrial robots, vision systems, custom hardware, and quality control measurement techniques. - Robotic Integration: Implementing automation systems encompassing all forms of robotics, including pick and place, Cartesian, SCARA, and 4 and 6-axis robots. - Automated Testing: Developing semi- and fully-automated test devices for manufacturing lines to improve product quality and increase efficiency. How does automation benefit Texas manufacturers working with Deaton Engineering? Automation helps Texas manufacturers: - Enhance Efficiency: Streamline operations and reduce labor costs. - Improve Quality: Achieve consistent and precise manufacturing outcomes. - Increase Competitiveness: Optimize capital and labor resources to become more cost-competitive. What industries in Texas can benefit from Deaton Engineering's automation services? Deaton Engineering's automation solutions can benefit industries such as food and beverage, pharmaceuticals, medical devices, semiconductors, and general manufacturing. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How can Texas businesses start an automation project with Deaton Engineering? Businesses can initiate projects by [contacting Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visiting their Georgetown, Texas headquarters, a suburb of Austin, for consultations. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. Test Engineering, Quality Assurance & Quality Control Automated Test Solutions to Guarantee Product Quality and Reduce Manufacturing Risks Global competition, customer demands, and various regulatory bodies have put more emphasis on quality control and quality assurance. Quality has become a key product differentiator and a manufacturing necessity by providing plant managers with the information they need to make strategic decisions. If your company requires fast, easy access to data for insights into operational processes, Deaton Engineering can help. We will team with you to design, build, and implement robust, continuous online quality verification systems. We also design custom test equipment and develop test plans to ensure quality. Custom Test and Quality Assurance for Improved Process & Manufacturing Robustness, and Reliability Fully Automated System Testers Deaton Engineering designs and builds semi- and fully automated test systems to meet your test specification criteria. DEI can develop test systems using any Fully Automated System Testers Deaton Engineering designs and builds semi- and fully automated test systems to meet your test specification criteria. DEI can develop test systems using any development platform. Integrated Quality Assurance & Quality Control Systems Deaton Engineering teams with you to integrate quality control systems that ensure product quality and cost efficiency. We design real-time quality verification Deaton Engineering teams with you to integrate quality control systems that ensure product quality and cost efficiency. We design real-time quality verification systems that meet security demands and government regulations. Our integrated solutions help your company respond to business initiatives throughout the plant. Deaton Engineering designs and builds custom test fixtures that reduce labor costs and make final assembly more efficient. Our engineers provide innovative solutions to automate, simplify, and improve your current manufacturing processes. Test Engineering, Quality Assurance & Quality Control Services Quality assurance (QA) Quality control (QC) Quality control (QC) Quality management Quality management Electrical and squib test Electrical and squib test Data acquisition Data acquisition Machine vision Machine vision Inspection equipment Inspection equipment Mechanical test Automated test equipment (ATE) Test automation & controls Test engineering Manufacturing quality control Functional testers Automated system testers Test plan development Functional testers Test automation & controls Test engineering Manufacturing quality control Pharmaceutical quality control Pharmaceutical quality control Custom test equipment Quality assurance testing Automated system testers Custom test fixtures Custom test equipment Quality assurance testing Functional tester Integrated test systems Integrated quality control systems Integrated quality control systems Motion system controls Motion system controls Factory acceptance testing (FAT) Failure modes & effects analysis (FMEA) Custom test fixtures Integrated test systems Failure modes & effects analysis (FMEA) Design of experiments (DOE) Functional tester Statistical process control (SPC) Software engineering & process control Gage repeatability and reproducibility (R&R) Statistical process control (SPC) Software engineering & process control Engineering services Software engineering & process control Engineering services Machine design, mechanical & electrical engineering Engineering services Machine design, mechanical & electrical engineering Process and manufacturing equipment list Process and manufacturing equipment list # Contract Manufacturing Services (CMS) & Engineering ## An Alternative to Offshore Contract Manufacturing Offshore manufacturing is often necessary for mature products to control costs and remain competitive. However, taking this step too early can severely hinder your efforts to get your best product to market quickly. An engineering and low-volume manufacturing partner can save you time and money by helping you develop and manufacture your product until its ready to be transitioned to overseas production. This is certainly the case in early stages of product development where volumes are uneven, engineering is incomplete, and assembly documentation is nonexistent. Deaton Engineering can help you keep pace with engineering changes on the fly while meeting your low-volume manufacturing needs. Your product will be managed by experienced engineers and built by skilled in-house technicians through this volatile transition period. Once the product has matured, Deaton Engineering can produce assembly instructions, drawings, procedures, and manufacturing bid packages to ease the transition to lower-cost manufacturing. ## Turnkey Design Services & Lean Manufacturing ### Product Development & Design-Alpha & Beta Phases Deaton Engineering can design the next-generation product as we build to meet current demand. Our designs reduce manufacturing and tooling costs and ease the transition to contract manufacturing. ### Build to Order Assembly & Lean Manufacturing Deaton Engineering can design your product, fulfill orders, and ship direct to your customers as required to meet demand. Your product will be built by skilled technicians who are adept at managing production changes. Quality is guaranteed. ### Vendor Sourcing and Transition to High-Volume Manufacturing Not only do we produce documentation necessary for the transition to high volume manufacturing, but we also help you identify the right manufacturing partner. We have contacts with a number of domestic and international firms to help get you started. ## Engineering, Manufacturing, & Design Services Custom part development Contract manufacturing organization (CMO) Lean manufacturing Contract manufacturing services (CMS) Box build Rapid prototypes & first articles Manufacturing engineering Program management Product manufacturing & assembly Timeline and budget development Electronic manufacturing & assembly Testing support: shock, vibration, & packaging Machine manufacturing & assembly Assembly instructions Insourcing & inshoring Purchased part specification Flexible manufacturing Detailed bill of materials (BOM) Computer aided manufacturing (CAM) Vendor management Mechanical & electrical assembly Manufacturing bid packages Manufacturing on demand Prototype development & verification Enclosure assembly Design for manufacture Startup manufacturing Test engineering and quality assurance Low volume manufacturing Engineering services list Cable and harness assembly Manufacturing services list Electromechanical assembly Product development experience list ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### Manufacturing Streamline: # Deaton Drives Efficiency for Honda Facility [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-honda.pdf) ![Deaton Drives Efficiency for Honda Facility](https://www.deatonengineering.com/images/photo-header-honda.jpg) ## The Client: Honda Motor Co., Ltd. Tier 1 Supplier Honda manufactures a wide array of vehicles for a world of diverse needs and lifestyles. All Honda vehicles demonstrate their leadership with high performance, superior fuel economy, optimum safety, and driving pleasure. Honda's unique innovation has earned respect worldwide. That’s how they sell more than 3.5 million vehicles around the globe each year. ![](https://www.deatonengineering.com/images/logo-honda.svg) ## The Challenge: Semi Automated Manufacturing Line for Mexico Our customer, a tier 1 supplier to Honda and other car manufacturers, needed to expand their manufacturing capacity in their Mexican facility. The challenge, design and fabricate a semi-automated manufacturing line to assemble and test airbag horn assemblies at a rate of 1 every 29 seconds. The new design had to be flexible enough to handle 19 product variations, reduce product change over time and meet strict Automotive TS 16949:2002 standards for quality and record keeping. ## The Solution: Manufacturing Line Capable of Running 19 Product Variations Deaton Engineering designed a manufacturing line that integrated quality assurance and test. We incorporated a poka-yoke design to eliminate left hand or right hand part substitution errors. The human-machine interfaces (HMIs) provided assembly instructions in the operator's language and controlled all machine operations. We were able to automate the manufacturing process and critical testing while taking advantage of low cost labor to move subassemblies from station to station. The time required to change over a line was greatly reduced by having the machines pre-configured according to bar coded part numbers. ## Engineering Highlights: - Product change over was reduced from 6 hours to less than 2 hours - 11 stations including: electrical testing, ultrasonic welding, mechanical testing and final packout. - Bar code part & subassembly management over a secure wireless network, records retained for 30 years. - Parts are locked down if test detects failure - only authorized personnel can release part. - Universal design capable of handling 19 product variations. - Additional manufacturing lines were designed for Brazilian facility. ![](https://www.deatonengineering.com/images/honda-cs-line.jpg) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # Machine Design, Mechanical Engineering & Electrical Engineering ## Machine & Equipment Designed to Meet Today's Global Standards Industry leaders have learned that to maintain a competitive advantage in the global marketplace you must continually improve your operation. But efforts to implement change must be weighed against the constant pressure of lower margins, higher demand, and what seems to be a continually shrinking pool of resources. Deaton Engineering can help by integrating technology solutions while you stay focused on core competencies. We can even integrate production data directly into your ERP system to provide real-time analysis capabilities. ![Solidworks Certified Partner](https://www.deatonengineering.com//images/logo_partner_solidworks.gif) Well engineered solutions are a necessity to stay ahead of the efficiency curve. The experts at Deaton Engineering can design, build, install, and validate custom equipment to help your plant work smarter. We use off-the-shelf equipment and open standards whenever possible to create solutions that can evolve over time. We find the best solution to your problem by not promoting component manufacturers. Our products can be designed to meet global regulations and required certifications including UL, CE, ANSI and others. We understand the impact of regulatory requirements and design equipment with validation and compliance in mind. ![Machine Design, Mechanical Engineering & Electrical Engineering](https://www.deatonengineering.com/images/img-lathe.jpg) ## Design, Simulate, Build, and Test ### Turnkey Machine Design and Build Deaton Engineering designs and builds custom equipment for many industries from [pharmaceutical](https://www.deatonengineering.com/industries/pharmaceutical.php) to heavy machinery. We design turnkey machines, enclosures, electrical systems, mechanisms and process controls. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. ### Customized Electrical Equipment & Electronics Certain solutions simply cannot be implemented using only off-the-shelf equipment. Whether it is a straightforward design involving signal conditioning or a more complex design involving full wireless data transmission, Deaton Engineering can provide complete design and build services. Our electrical engineers design custom components including control panels, cable harnesses, electrical drawers, signal conditioning, AC/DC power distribution blocks, wireless devices, low-power embedded controllers, data acquisition units and machine safety circuits. Deaton Engineering uses the latest methodologies and design practices, allowing for more efficient and low-maintenance designs. Our in-house PCB capabilities (schematic capture, layout, procurement, assembly & test) cover multi-layer, high-speed, low/high power, and small footprint designs (i.e., BGA). This results in finished products ranging from single-layer interface boards to multi-layer high-speed ARM-based microcontroller units; from large electromechanical relay boards to miniaturized wireless devices. ### Designed for Good Manufacturing Practices (GMP) & Validation To ensure our designs meet current GMP requirements, we follow the GAMP life cycle model for automated systems to facilitate [validation](https://www.deatonengineering.com/services/validation.php). We design and build individual pieces of equipment or complete manufacturing lines to [automate](https://www.deatonengineering.com/services/automation.php) and improve the manufacturing process. ## Machine Design, Mechanical Engineering & Electrical Engineering Services - Mechanical engineering - Electrical engineering - Power usage design & management - Embedded systems - Machine design - Equipment design - Machine safety & machine guarding - Servo & stepper motors - Motion control, linear actuators - OSHA & ANSI design - Machine vision - Electronic engineering - Electromechanical design - Industrial control - Design for quality & validation - Cable & connector design - Electrical system integration - Chassis, enclosure, and panel design - Rugged & hardened design - Sheet metal & plastic design - International standards; CE, UL, & RoHS - Parametric design - [Software & controls systems](https://www.deatonengineering.com/services/softwareengineering.php) - [Measurement & inspection systems](https://www.deatonengineering.com/services/customtest.php) - [PLC, HMI and computer control](https://www.deatonengineering.com/services/softwareengineering.php) - [Industrial robots](https://www.deatonengineering.com/services/automation.php) - [Process and manufacturing equipment list](https://www.deatonengineering.com/services/machineequipment.php#) - [Engineering services list](https://www.deatonengineering.com/services/machineequipment.php#) - [Manufacturing services list](https://www.deatonengineering.com/services/machineequipment.php#) - [FDA, regulatory and safety services list](https://www.deatonengineering.com/services/machineequipment.php#) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/machineequipment.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/machineequipment.php#carouselExampleIndicators) #### FAQs: What machine and equipment design services does Deaton Engineering offer in Texas? Deaton Engineering provides: - Custom Machine Design: Creating tailored machinery to meet specific operational needs. - Mechanical and Electrical Engineering: Developing integrated systems combining mechanical components with electrical controls. - Equipment Upgrades: Enhancing existing machinery to improve performance and extend lifespan. How does Deaton Engineering ensure compliance with Texas regulations in machine design? Deaton Engineering designs equipment to meet global regulations and required certifications, including UL, CE, ANSI, and others, ensuring compliance with federal and Texas state standards. Can Deaton Engineering assist with integrating new equipment into existing Texas facilities? Yes, Deaton Engineering designs custom equipment to be easy to install, operate, and maintain with minimal engineering support, facilitating seamless integration into existing facilities. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How can Texas manufacturers initiate a machine design project with Deaton Engineering? Manufacturers can [contact Deaton Engineering here](https://www.deatonengineering.com/contact.php) or by visiting their Georgetown, Texas headquarters, a suburb of Austin, to discuss machine and equipment design needs. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. DEATON ENGINEERING YOUR VISION, OUR PRECISION CASE STUDY Deaton Engineering designs and integrates automated processing equipment for novelty ice cream production Ice Cream Novelty Products: Concept to Production Deaton Engineering turns 2D drawings of novelty cartoon characters into 3D designs suitable for extrusion and production. Product design and size are based on customer's equipment capacity. - Stick slices - Sandwiches - Slices - Cups - Cones - Bars The Challenge: Design & Fabrication of Ice Cream and Water Ice Horizontal & Vertical Extruders and Nozzles The Solution: Custom extrusion equipment built for the demands of commercial production and compliance Deaton Engineering designs and fabricates ice cream and water ice horizontal and vertical extruders and nozzles. Our extruders are designed using parametric models to ensure they meet delivery and production requirements, and work the first time. The extruders can be designed for both new and existing product lines. Deaton Engineering understands sanitary design and manufacturing. DEI incorporates these principals into every extruder we design and fabricate. * * * Extruders & Nozzles-Horizontal & Vertical / Single-flavor single-outpu≈ / Single-flavor multi-outpu≈ / Multi-flavor multi-outpu≈ / Complex multi-flavo / Log products ## Product Handling Equipment / Stick gripper modifications and redesigH / Stickless pickup deviceD / Cone pickup devices ## Chocolate Coating & Enrobing / Custom or product specific coating and/or enrober modifications ## Other Components & Equipment / Wafer DispenserD / Nut & Candy DispenserD / Conveyors # Machine Improvements: / PLC programming & desigH / AutomatioH / Clean, sanitary re-desigH / Cooling & hardening tunnel modificationD / Liquid nitrogen applicationD / Special application cutterD / Electronic drive retrofit # EPA Mandated Risk Management Plan and Program (RMP): ## / RMP for ammonia refrigeration systems ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) [![Click to verify BBB accreditation and to see a BBB report.](https://www.deatonengineering.com/images/bbbseal1.gif)](http://www.bbbonline.org/cks.asp?id=1081208153544) # Privacy Notice This privacy notice discloses the privacy practices for [http://www.deatonengineering.com/](http://www.deatonengineering.com/). This privacy notice applies solely to information collected by this web site. It will notify you of the following: 2. What personally identifiable information is collected from you through the web site, how it is used and with whom it may be shared. 4. What choices are available to you regarding the use of your data. 6. The security procedures in place to protect the misuse of your information. 8. How you can correct any inaccuracies in the information. **Information Collection, Use, and Sharing** We are the sole owners of the information collected on this site. We only have access to/collect information that you voluntarily give us via email or other direct contact from you. We will not sell or rent this information to anyone. We will use your information to respond to you, regarding the reason you contacted us. We will not share your information with any third party outside of our organization, other than as necessary to fulfill your request. Unless you ask us not to, we may contact you via email in the future to tell you about specials, new products or services, or changes to this privacy policy. **Cookies** We may or may not choose to use “cookies” in the future. A cookie is a piece of data stored on a visitor's hard drive to help us improve your access to our site and identify repeat visitors to our site. For instance, when we use a cookie to identify you, you would not have to log in a password more than once, thereby saving time while on our site. Cookies can also enable us to track and target the interests of our users to enhance the experience on our site. Usage of a cookie is in no way linked to any personally identifiable information on our site. **Links** This web site contains links to other sites. Please be aware that we are not responsible for the content or privacy practices of other sites. We encourage our users to be aware when they leave our site and to read the privacy statements of any other site that collects personally identifiable information. **Your Access to and Control Over Information** You may opt out of any future contacts from us at any time. You can do so by contacting us at the phone number on our website. **Security** This site has security measures in place to protect the loss, misuse and alteration of the information under our control. If you feel that we are not abiding by this privacy policy, you should contact us via telephone at 800-930-9908. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) [![](https://www.deatonengineering.com/images/icn_pdf.gif)](https://www.deatonengineering.com/pdfs/industries/pharmaceutical.pdf "Download PDF") # Pharmaceutical Engineering ## Deaton Engineering Understands Good Manufacturing Practices (GMP) The impact of long product development cycles, global competition, and current Good Manufacturing Practices presents a unique challenge to the pharmaceutical industry. When designing or changing a process, great care must be taken to balance international regulatory requirements with efficiency and cost. Managing these requirements makes pharmaceutical engineering a discipline unto itself. Whether you are scaling up a new process or modifying an existing one, Deaton Engineering can help. Our risk-based approach to pharmaceutical engineering is a proven strategy for managing process design, development, and change. Deaton Engineering partners with you to determine the best solution to meet your goals. ![Total quality management: define, design, build, validate, and improve.](https://www.deatonengineering.com/images/tqi.png)Our engineering teams are highly skilled and experienced with the latest technologies. We deliver innovative equipment and system solutions using nonproprietary technologies (including open standards whenever possible) to accelerate adoption and simplify [validation](https://www.deatonengineering.com/services/validation.php). Deaton Engineering understands current GMP requirements and follows the proven **Total Quality Approach** to providing engineered solutions. This approach can deliver substantial improvements in productivity while maintaining the highest assurance of product and human safety. ## Process & Facilities Optimization, Equipment Automation, and Regulatory Compliance ### Machine Design & Process Automation Deaton Engineering can [design and build](https://www.deatonengineering.com/services/machineequipment.php) an individual piece of equipment or a complete manufacturing line to [automate](https://www.deatonengineering.com/services/automation.php) and improve your process. We use GAMP-compliant designs to create turnkey solutions that are reliable, cost-effective, and suitable for GMP [validation](https://www.deatonengineering.com/services/validation.php). Deaton Engineering can also help identify, integrate, and validate your [Process Analysis Technology (PAT)](https://www.deatonengineering.com/services/customtest.php) solutions. ### Process Engineering, Facilities, and Safety Deaton Engineering provides support services for production and utility systems in FDA-approved [facilities](https://www.deatonengineering.com/services/facilitiesprocess.php). Our engineers can design, improve, or support the systems that run your operation -- including on-site construction management and start-up -- to help you every step of the way. ### Risk-Based Validation Engineering and FDA Compliance Our engineers provide turnkey [validation services](https://www.deatonengineering.com/services/validation.php) that cover the entire validation process. We can develop and execute qualification protocols for equipment, [facility systems](https://www.deatonengineering.com/services/facilitiesprocess.php), and processes. Our documentation packages are extremely thorough and comply with regulatory requirements. Deaton Engineering can perform validations of [automated control systems](https://www.deatonengineering.com/services/softwareengineering.php) in accordance with 21 CFR Part 11. ## Pharmaceutical Engineering Services - Process analysis technology (PAT) - FDA, GMP, cGMP compliance & design - Current good manufacturing practice (cGMP) (GMP) - Good automated manufacturing practice (GAMP) - Quality assurance & quality control - USP purified water, water for injection (WFI) - Design of experiments - Pharmaceutical consultants - Aseptic process & equipment design - Quality by design - Bioprocess engineering - Standard operating procedures (SOP) - User requirements specifications (URS) - Functional requirements specifications (FRS) - Software requirements specifications (SRS) - Installation qualifications (IQ) - Operational qualifications (OQ) - Performance qualifications (PQ) - 21 CFR Part 11 - Process development & optimization - Clean and sanitary design practices - System design specifications - Measurement system analysis - Statistical process control - Automated process control systems (APCS) - On-site construction management and start-up support - System commissioning - [Process and manufacturing equipment list](https://www.deatonengineering.com/industries/pharmaceutical.php#) - [Process engineering services list](https://www.deatonengineering.com/industries/pharmaceutical.php#) - [Facilities engineering services list](https://www.deatonengineering.com/industries/pharmaceutical.php#) - [Validation engineering services list](https://www.deatonengineering.com/industries/pharmaceutical.php#) - [FDA, regulatory and safety services list](https://www.deatonengineering.com/industries/pharmaceutical.php#) #### FAQs: What pharmaceutical engineering services does Deaton Engineering offer in Texas? Deaton Engineering provides a comprehensive suite of pharmaceutical engineering services, including: - Process Analysis Technology (PAT): Implementing advanced monitoring and control systems to enhance process efficiency. - FDA, GMP, and cGMP Compliance & Design: Ensuring all processes and designs meet stringent regulatory standards. - Aseptic Process & Equipment Design: Developing sterile systems to maintain product integrity. - Validation Services: Conducting thorough qualifications such as IQ, OQ, and PQ to ensure system reliability. - Automated Process Control Systems (APCS): Designing and integrating automation solutions for consistent production quality. These services are tailored to meet the unique needs of pharmaceutical companies operating in Texas. Deaton provides engineering and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. How does Deaton Engineering ensure compliance with Texas-specific pharmaceutical regulations? Deaton Engineering stays abreast of both federal and Texas state regulations governing drug manufacturing and distribution. They ensure that all projects comply with guidelines set forth by the Texas Department of State Health Services (DSHS), including adherence to state-specific statutes and federal laws adopted by reference. [Texas Health and Human Services](https://www.dshs.texas.gov/drug-manufacturers-distributors/state-federal-laws-drug-manufacturers-distributors) Can Deaton Engineering assist with facility optimization and safety in Texas-based pharmaceutical plants? Yes, Deaton Engineering offers support services for production and utility systems in FDA-approved facilities across Texas. Their engineers can design, improve, or support systems that run operations, including on-site construction management and start-up support, ensuring efficiency and safety standards compliance. What is Deaton Engineering's approach to process automation for Texas pharmaceutical companies? Deaton Engineering designs and builds individual equipment or complete manufacturing lines to automate and improve processes. They utilize GAMP-compliant designs to create turnkey solutions that are reliable, cost-effective, and suitable for GMP validation, catering to the specific needs of Texas pharmaceutical manufacturers. How does Deaton Engineering support risk-based validation and FDA compliance in Texas? Their engineers provide turnkey validation services covering the entire validation process. They develop and execute qualification protocols for equipment, facility systems, and processes, ensuring documentation complies with regulatory requirements. Additionally, they perform validations of automated control systems in accordance with 21 CFR Part 11, which is crucial for Texas companies seeking FDA compliance. Does Deaton Engineering offer consulting services for Texas pharmaceutical companies? Yes, they provide pharmaceutical consulting services, including process development and optimization, quality assurance and control, and the development of standard operating procedures (SOPs), all tailored to the needs of the Texas pharmaceutical industry. How can Texas pharmaceutical companies initiate a project with Deaton Engineering? Companies can contact Deaton Engineering through its website or by visiting its Georgetown, Texas, headquarters. It offers free consultations to discuss potential projects and provide estimates, facilitating collaboration with Texas-based pharmaceutical firms. Deaton provides engineering and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) # Capable and Versatile Engineering Services At Deaton Engineering, we bridge the gap between complex challenges and market-ready solutions. Our multi-disciplinary team provides comprehensive engineering services—from electromechanical design and prototyping to full-scale manufacturing and regulatory compliance. Whether you are scaling a single component or developing a complete industrial system, we provide the technical expertise and precision required to bring your vision to life. [One-Page Overview](https://www.deatonengineering.com//pdfs/deaton-engineering.pdf "Download a Quick Data Sheet") ![Complex Machine Automation](https://www.deatonengineering.com/images/feature-services.jpg) ## Services Deaton Engineering specializes in the following engineering services: ##### Finite Element Analysis Evaluate, analyze, and optimize performance and reliability of product design and manufacturing processes. [Learn More ❯](https://www.deatonengineering.com/services/elementanalysis.php) ##### Complex Machine Design Designing original complex machines and industrial equipment is our sweet spot. [Learn More ❯](https://www.deatonengineering.com/services/complex-machine-design.php) ##### Software Engineering and Process Control Maximize efficiency with information management and superior control systems. [Learn More ❯](https://www.deatonengineering.com/services/softwareengineering.php) ##### Product Development & Design Engineering Market driven product development from concept to manufacture. [Learn More ❯](https://www.deatonengineering.com/services/productdevelopment.php) ##### Process & Facilities Engineering Process engineering, facilities engineering, and process & plant safety management. [Learn More ❯](https://www.deatonengineering.com/services/facilitiesprocess.php) ##### Automation Engineering & Robotics Design, development, and implementation of advanced automation systems. [Learn More ❯](https://www.deatonengineering.com/services/automation.php) ##### Test Engineering, QA & QC Automated test solutions to guarantee product quality and reduce manufacturing risks. [Learn More ❯](https://www.deatonengineering.com/services/customtest.php) ##### Validation Engineering We specialize in helping clients succeed across the full spectrum of validation and compliance challenges. [Learn More ❯](https://www.deatonengineering.com/services/validation.php) ##### Mechanical & Electrical Engineering Machine & equipment designed to meet today’s global standards. [Learn More ❯](https://www.deatonengineering.com/services/machineequipment.php) ##### Contract Manufacturing Services (CMS) Turnkey design services & lean manufacturing to perfect your product domestically [Learn More ❯](https://www.deatonengineering.com/services/lowvolumemanufacturing.php) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) ENGINEERING SERVICES # FEA - Finite Element Analysis & Design Optimization ## Evaluate, Analyze, and Optimize Performance and Reliability of Product Design and Manufacturing Processes To successfully deploy new products, you have to move quickly to get an edge in the market. And while product life cycles get ever shorter, the cost of warranty and service is on the rise. The traditional design-prototype-test approach to new [product development](https://www.deatonengineering.com/services/productdevelopment.php) can be slow and inefficient when problems are encountered. Deaton Engineering uses Finite Element Analysis (FEA) to accurately model products and processes. Our techniques can measure performance, reliability, wear points and predict failures long before you commit to tooling or start to build. We are adept at helping companies improve profitability by dramatically reducing development time, rework and quality issues. Our approach will help you speed up the design process through rapid optimization. ![Finite Element Analysis](https://www.deatonengineering.com/images/header-fea.jpg) ## Design, Simulate and Virtually Test with FEA Services ### Design Optimization Our goal is to reduce product development costs and improve quality. FEA helps solve design challenges without arduous manual iterations or prototyping. ### Solution Verification and Validation Experienced mechanical engineers verify all FEA findings against empirical test data, simplified models, and classical calculations to ensure accuracy. 3-D modeling is also used to validate designs. ### Computational Methods to Support Regulatory Filings for Medical Devices Utilize FEA to reduce product development costs, limit liability risk, reduce time to market, and support FDA 510k filings. Identify and analyze worst-case implantable device size for use in mechanical testing. Verify radial force, anchoring, dynamic compliance, and fatigue loading conditions. ## FEA & Design Optimization Services ### FEA for Regulatory Compliance - Computational testing - Identifying worst-case device sizes - In vivo loading conditions - Anchoring and fatigue loading conditions - Design verification and validation ### Linear Analysis - Static analysis - Stress analysis - Stress engineering - Strain analysis - Critical buckling loads - Natural frequency - Modal analysis - Frequency response - Response spectrum - Random vibration - Mechanical analysis ### Nonlinear Analysis - Nonlinear materials - Creep and viscoelasticity - Plasticity - Temperature dependent materials - Load and/or geometric stiffening - Large displacements - Large strain formulations - Dynamic loading & analysis - Contact stress - Impact loading ### Thermal - Steady state heat transfer - Transient analysis - Thermal stress - Thermal design optimization - Airflow & pressure characterization - Thermal engineering ### Specialty Analysis - Seismic analysis - Wind loading - Snow & ice loading - [Finite element services list](https://www.deatonengineering.com/services/elementanalysis.php#) - [Engineering services list](https://www.deatonengineering.com/services/elementanalysis.php#) ## Working With Deaton Engineering We strive to help you integrate current technologies into new products, achieve superior ROI, accelerate time to market, and create a positive business impact. Our custom equipment is designed to be easy to install, operate, and maintain with minimal engineering support. Our goal is to lower your cost of ownership by minimizing training, operator intervention, downtime, and revalidation. #### 1\. Is Deaton Engineering a good fit? Our best customers are interested in new ideas and open to following a proven process. Our clients freely share details of their challenges & goals, how decisions are made, who cares about them, and why they are considering this project now. #### 2\. Does a solution exist that’s off the shelf? If yes, then source it. If not... We provide turnkey machine design from concept through manufacture. #### 3\. Is the problem worth solving? What is the economic value of the issue to be solved? Deaton follows a discovery process designed to identify if there are problems worth solving, if what we offer can help them and if they’re a good fit for the niche our company serves. #### 4\. Defining the problem and the scope of work We employ a Total Quality Improvement methodology for design, validation, and manufacturing. We partner with you to develop and deliver innovative engineering solutions to support your project initiatives. Deaton Engineering can help you create a strategic plan for machine and technology investment decisions based on your needs. #### 5\. Setting up a path to successful machine design, a phased-based approach We follow a phase-based approach to machine design and innovation that includes defining user requirements, design conceptualization, development, prototyping, testing, and manufacturing preparation. [Previous](https://www.deatonengineering.com/services/elementanalysis.php#carouselExampleIndicators) [Next](https://www.deatonengineering.com/services/elementanalysis.php#carouselExampleIndicators) #### FAQs: What Finite Element Analysis (FEA) services does Deaton Engineering offer in Texas? Deaton Engineering provides comprehensive FEA services to Texas clients, including: - Structural Analysis: Assessing stress, strain, and deformation in components and assemblies. - Thermal Analysis: Evaluating temperature distribution and heat transfer within systems. - Dynamic Analysis: Analyzing vibrations, impacts, and time-dependent behaviors. - Fatigue and Failure Analysis: Predicting product lifespan under cyclic loading conditions. How does Deaton Engineering's FEA expertise benefit Texas industries? By leveraging FEA, Deaton Engineering assists Texas industries in: - Optimizing Designs: Enhancing product performance while reducing material costs. - Ensuring Compliance: Meeting industry standards and Texas-specific regulations. - Accelerating Time-to-Market: Identifying and resolving potential issues early in the design process. Can Deaton Engineering's FEA services be integrated with other engineering solutions? Yes, Deaton Engineering integrates FEA with services like Complex Machine Design and Product Development, providing holistic solutions to Texas clients. How can Texas businesses engage Deaton Engineering for FEA services? Texas businesses can [contact Deaton Engineering here](https://www.deatonengineering.com/contact.php) or visit their Georgetown, Texas headquarters, a suburb of Austin, to discuss FEA project needs. Deaton provides engineering, design, automation, and validation services across Texas, including in Austin, Dallas, Fort Worth, Waco, Houston, and San Antonio. ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) #### On Time and Under Budget: # Deaton Delivers the COW to the Classroom [Download PDF >](https://www.deatonengineering.com/pdfs/case_studies/case-study-ignite.pdf) ![Ignite! Learning case study header](https://www.deatonengineering.com/images/header-ignite.jpg) ## The Client: Ignite! Learning Ignite! is a company committed to helping teachers by creating reliable, effective, and fun educational media. The company's flagship product is the Curriculum On Wheels (COW), a flexible multimedia curriculum tool designed to deliver comprehensive science and social studies media content to students in a motivational and engaging way. School districts and public and private schools in Texas, South Carolina, Virginia, Georgia, Tennessee, Louisiana, Nevada and California have adopted the Ignite! Curriculum on Wheels to help improve student performance in science, social studies and history. ![](https://www.deatonengineering.com/images/logo-ignite-2.png) ## The Challenge: Prototype & Build Ignite! came to Deaton Engineering with an urgent need to design and prototype their product concept and begin shipments in just six weeks. The device would be a self-contained unit featuring a built-in computer, LCD projector and speakers. The overriding requirement was that elementary and middle school teachers would be able to simply plug in the device and begin a lesson. ## The Solution: An Imaginative COW ![](https://www.deatonengineering.com/images/photo_ignite_2.jpg) Deaton Engineering created a winning design in just a couple of weeks. In a very short timeframe, we worked in tandem with our rapid prototype partners to deliver a Sterolithography (SLA) enclosure. DE and Ignite! selected the internal components to be incorporated into the product. In the next phase of the project, we optimized the design for manufacture by selecting a thermoforming vendor that could meet the tight manufacturing budget. Our attention to detail ensured the COW would be UL and CE compliant. ## Engineering Highlights: - Delivered the award-winning "Curriculum on Wheels" on time and on budget - Developed manufacturing and quality assurance procedures - Designed versions for US and International markets - Manufactured the first 1,000 units - Provided fulfillment services and drop shipped units worldwide - Transitioned manufacture to lower cost domestic contract manufacturer ![](https://www.deatonengineering.com/images/photo_ignite_1.jpg) ![Deaton Engineering](https://www.deatonengineering.com/images/deaton-logo.png)![](https://www.deatonengineering.com/images/deaton-address-print.png) # Our Expertise Meets Compliance Needs Precision engineering requires a deep understanding of the environments in which your products must perform. Deaton Engineering serves a diverse range of sectors—including medical, industrial, and energy—where safety, reliability, and regulatory standards are paramount. We leverage our cross-industry experience to solve unique challenges, ensuring every project meets the rigorous technical demands and compliance benchmarks of your specific field. [One-Page Overview](https://www.deatonengineering.com//pdfs/deaton-engineering.pdf "Download a Quick Data Sheet") ![Pharmaceutical Automation](https://www.deatonengineering.com/images/feature-industries.jpg) ## Industries We have worked with industries that demand both high-precision and scalable efficiency, including, but not limited to: ##### Pharmaceutical Engineering Pharmaceutical engineering with a risk-based approach to FDA compliance and good manufacturing practices. [Learn More ❯](https://www.deatonengineering.com/industries/pharmaceutical.php) ##### Food, Beverage & Dairy Engineering & automation services for the Food, Beverage, and Dairy industries. [Learn More ❯](https://www.deatonengineering.com/industries/foodbeverage.php) ##### Medical Device Design Biomedical engineering and medical device design that meets FDA requirements. [Learn More ❯](https://www.deatonengineering.com/industries/medicaldevices.php)