Consulting Services

Our consulting services are designed to address your most challenging engineering problems.

Engineering Solutions for Your Biggest Challenges

With a focus on failure analysis, diagnosing issues, optimising processes, and implementing tailored solutions, we ensure your operations run smoothly and efficiently. Check out our case studies below.

Landcruiser Power Steering System Failure

Landcruiser Power Steering System Failure

The Problem:
Toyota Landcruiser power steering systems were exposed to extreme environmental conditions, causing the power steering oil to overheat and leading to premature seal failures in the pump and motor every 6-8 weeks. This resulted in an Australia-wide shortage of these components.

The Solution

Through consultation period with the customer, Ferrum Engineering increased the system oil volume using a 3D-printed purpose built tank, extending failure time to 8 months. With a fleet of over 50 Landcruiser’s, this resulted in reduced downtime and significantly increased availability. This seamless integration improved reliability, performance, and safety by managing fluid temperature and reducing component failures. Ferrum Engineering is still working with this customer to improve on the new MTBF.

Designed For

Like-for-like replacement of the OEM oil tank, mounting to existing points, and utilising existing hoses for easy integration.

Work Smarter:

Utilising advanced 3D printing materials and processes, Ferrum Engineering created lightweight, robust tanks, ensuring smarter, cost-effective solutions.

Anti Tamper Dash Camera Cases

Anti Tamper Dash Camera Cases

The Problem:

The customers faced frequent tampering of dash cameras in vehicles operating in high-risk environments. Due to this tampering data was often loss, erased or simple not recorded in the first place due to tempering of the equipment’s power supply.

The Solution

Ferrum Engineering designed and developed anti-tamper dash camera cases, utilising advanced CAD modelling and 3D printing technology for rapid prototyping and customisation. These cases provide robust protection against tampering and theft, ensuring the integrity and security of the dash cameras.

Designed For

Our anti-tamper dash camera cases are designed for easy installation, seamlessly integrating with existing dash camera systems. The rugged construction ensures durability in harsh conditions, providing long-lasting security.

Work Smarter:

By employing high-quality 3D printing materials and innovative design, Ferrum Engineering created a cost-effective solution that minimises downtime and protects valuable equipment. The use of 3D printing eliminated the need for costly injection moulding, while still utilising UV and temperature-resistant materials for runs of up to 1000 units and keep production in Australia. Our anti-tamper cases ensure that dash cameras remain secure, operational, and reliable, even in challenging environments.

Pre-Set Engine Belt Tension System - Increased Reliability & Serviceability

Pre-Set Engine Belt Tension System - Increased Reliability & Serviceability

The Problem:
A customer faced frequent failures of engine belts in harsh environmental conditions, with an average time between failures of just 10 hours. The belts were failing due to incorrect tensioning and poor alignment caused by poorly designed OEM components, leading to significant downtime and maintenance costs.

The Solution

Ferrum Engineering developed a custom pre-set engine belt tension system to address this issue. The innovative design involved solidly mounting the alternator and introducing a separate, fixed-type tensioning system. This solution eliminated the need for springs and minimised moving parts, ensuring consistent belt tension, reducing the risk of human error during installation, and ensuring correct alignment every time. It also reduced the time to change out the belt to under 1 minute.

Designed For

Our Patented Pre-Set Engine Belt Tension System is designed for like-for-like replacement, mounting to existing points, and utilising existing components. This design simplifies installation and maintenance, making it an ideal solution for demanding environments.

Work Smarter:

By leveraging advanced engineering techniques, Ferrum Engineering created a robust and reliable belt tensioning system. This system not only eliminated human error by using a pre-set tension design but also significantly increased the Mean Time Between Failures (MTBF) from 10 hours to over 1000 hours. The solution proved to be highly effective, reducing downtime, enhancing reliability, and improving overall serviceability.

Glen, our lead engineer, prides himself on his unique ability to deconstruct problems and devise effective solutions. His extensive experience and innovative approach have consistently delivered exceptional results for our clients.

Whether it’s enhancing the reliability of a belt tensioning system or developing robust clamping mechanisms, Glen’s expertise ensures the highest standards of performance and reliability.

Learn more about Glen’s journey and expertise HERE .

With a wealth of experience and a passion for problem-solving, Glen and the Ferrum Engineering team are committed to finding solutions for even the most complex engineering challenges.

Explore our consulting services to see how we can help you achieve your operational goals.

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About us

We believe that attention to detail is the difference between “that’ll do” and exceptional, and we aim to achieve nothing but the highest quality service and products.