Fast turnaround R&D.
Specialized fabrication.
Full-stack engineering.
ALT provides end-to-end core engineering services for product development teams, research institutions, and Physical AI system builders — from initial CAD and simulation through additive manufacturing, reverse engineering, tooling, and systems integration. One team, one point of contact, US-based in Santa Barbara, CA.
Most engineering service providers do one thing — CAD, or fabrication, or simulation. ALT does all of them, under one roof, with one engineering team — so your project moves from concept to physical hardware without handoffs, format conversions, or vendor coordination overhead.
Core engineering service areas.
ALT's six core engineering service areas cover the full product development lifecycle — from initial design and analysis through fabrication, integration, and deployment. Each service is available independently or as part of a full-stack engagement.
Reverse engineering & CAD modeling
Convert physical parts, assemblies, and scanned geometry into fully parametric, editable CAD models — ready for modification, simulation, or manufacturing. ALT's SolidWorks and Blender workflow covers everything from undocumented legacy parts through complex organic geometries from 3D scan data.
- SolidWorks parametric CAD from scratch or scan data
- Reverse engineering of undocumented or legacy parts
- AI-assisted 2D image to 3D model conversion
- Design-for-additive-manufacturing (DfAM) optimization
- Drawing package generation — GD&T, tolerancing, BOM
- STEP, IGES, STL, OBJ, and native SolidWorks output
Additive manufacturing & rapid prototyping
End-to-end additive manufacturing from CAD file to finished part — in over 30 materials from standard PLA through PEEK, carbon fiber composites, TPU, and ALT's novel synthetic tissue and biomimetic composite materials. FFF, multi-material, and DLP resin processes in-house.
- Rapid prototyping — 24–48hr turnaround on standard geometries
- Engineering-grade materials: PEEK, Ultem, PAHT-CF, PPA-CF
- Multi-material gradient printing — rigid to flexible in one build
- Novel proprietary materials: synthetic tissues, biomimetic composites
- Small-batch production runs — 1 to 500 units
- Post-processing: sanding, painting, coating, hardware insertion
Simulation & engineering analysis
Finite element analysis, structural simulation, thermal analysis, and fluid dynamics — used to validate designs before fabrication and to optimize geometry for performance, weight, and manufacturability. ALT's simulation workflow reduces design iteration cycles and eliminates avoidable fabrication failures.
- FEA structural analysis — static, dynamic, fatigue
- Thermal simulation for electronics enclosures and heat-critical parts
- Topology optimization for weight reduction and additive manufacturing
- Generative design for load-path-optimized geometries
- Simulation-driven DfAM — design optimized for printability and performance
- Simulation reports for engineering validation and customer review
3D scanning & dimensional inspection
High-precision 3D scanning at 0.03mm accuracy and 0.07mm resolution — for reverse engineering, quality control, first article inspection, and digital twin creation. Marker-free AI-guided scanning for delicate or finished surfaces. Scan-to-CAD pipeline fully integrated with ALT's reverse engineering workflow.
- 0.03mm accuracy dimensional scanning — engineering and medical grade
- Marker-free scanning — no adhesive markers on finished surfaces
- Full-color 24-bit texture capture for anatomical and consumer applications
- Scan vs. CAD deviation mapping for QC and first article inspection
- Point cloud processing — noise reduction, gap fill, mesh optimization
- Deliverables: STL, OBJ, STEP, SolidWorks, deviation report PDF
Tooling, fixtures & production jigs
Rapid production of custom tooling, assembly jigs, inspection fixtures, soft tooling, and manufacturing aids — faster and lower-cost than CNC-machined equivalents for quantities under ~50 units. ALT's additive tooling capability supports new product introduction (NPI), low-volume production, and engineering validation builds.
- Custom assembly jigs and alignment fixtures
- Inspection fixtures for dimensional verification and go/no-go gauging
- Soft tooling for silicone overmolding and cast parts
- End-of-arm tooling for robotic pick-and-place
- Drill guides, bonding fixtures, and assembly aids
- Engineering materials: PC, Nylon, PETG-CF for functional fixture loading
Systems integration & Physical AI
ALT's differentiating capability — integrating hardware, embedded electronics, sensors, and edge AI into complete Physical AI systems. From sensor-embedded structural components to fully autonomous robotic platforms, ALT closes the loop between physical hardware and onboard intelligence in a way no single-discipline engineering service can.
- Embedded sensor integration — tactile, IMU, proximity, optical
- Edge AI deployment — on-device ML for robotics, prosthetics, drones
- Sensor fusion architecture — multi-modal real-time perception systems
- Agentic AI for engineering process automation
- Physical AI system builds — prosthetics, drones, biomimetic robots
- Full-stack: design → fabrication → electronics → AI → deployment
Engineering services across industries.
ALT's engineering service capability spans applications from medical devices and aerospace through consumer products, robotics, and defense. The same technical foundation — additive manufacturing, CAD, simulation, and Physical AI — applies across all of them.
Medical & healthcare
Biocompatible prosthetics, surgical training devices, anatomical models, synthetic tissue composites, and medical device components in PEEK, PPSU, and biocompatible resins.
Robotics & Physical AI
Full-stack Physical AI systems — from printed structural frames in CF composites through embedded sensor integration and edge AI deployment for autonomous operation.
Aerospace & defense
High-performance components in PEEK, Ultem, and PAHT-CF for demanding thermal and structural environments. Topology-optimized geometries for maximum strength-to-weight.
R&D & research institutions
Fast-turnaround research prototypes, custom laboratory equipment, experimental apparatus, and Physical AI research platforms for academic and government research teams.
Consumer products
Rapid prototyping and low-volume production of consumer products — from concept validation through pre-production builds and Kickstarter fulfillment runs.
Manufacturing & industrial
Production tooling, inspection fixtures, replacement parts, and QC systems for manufacturers — reducing tooling cost and lead time versus traditional machined alternatives.
Architecture & construction
Detailed scale models, custom architectural components, bespoke fixtures, and multi-color presentation models for design firms, developers, and construction companies.
Education & research
Teaching aids, anatomical education models, research-grade prototypes, and custom experimental apparatus for universities, schools, and non-profit research organizations.
From brief to delivered hardware — four stages.
ALT's engineering engagement process — structured to move fast, minimize rework, and deliver parts and systems that actually perform as specified.
Brief & scoping
Tell us what you need — functional requirements, materials, geometry constraints, timeline, and budget. We'll confirm feasibility, identify the right service mix, flag risks upfront, and provide a detailed scope and quote within one business day for most projects.
Design & analysis
CAD development, simulation, DfAM optimization, and topology optimization — all before fabrication starts. We validate the design against your requirements analytically, reducing the number of physical iterations needed and catching failure modes before they become failed parts.
Fabrication & integration
Parts printed, finished, and integrated on calibrated, process-controlled systems. For systems integration projects, electronics, sensors, and software are assembled and validated alongside the physical hardware. QC inspection at each stage before moving forward.
Delivery & support
Parts and systems delivered with full documentation — inspection reports, process parameters, material data sheets, and design files as applicable. ALT supports revision rounds, production scale-up, and ongoing engineering iteration as your project evolves.
Why ALT for core engineering services.
Most engineering service providers are single-discipline — CAD only, or fabrication only, or simulation only. ALT is genuinely full-stack: one team covers design through fabrication through Physical AI integration, with no handoffs between vendors.
Full-stack under one roof
CAD, simulation, scanning, additive manufacturing, tooling, electronics integration, and edge AI — all performed by the same engineering team. No vendor coordination, no file format translation, no finger-pointing when something doesn't fit. One point of contact from brief to delivered hardware.
Novel materials not available elsewhere
ALT's proprietary synthetic tissue composites, biomimetic ceramic composites, and gradient material printing processes are available exclusively through ALT. For Physical AI, prosthetics, and medical simulation applications, these materials aren't a commodity — they're the capability.
Physical AI integration capability
ALT is one of the only engineering service providers that designs and deploys the intelligence layer — edge AI, sensor fusion, agentic perception — alongside the physical hardware. If your project requires hardware that thinks, ALT builds the full system.
Engineering judgment, not just execution
ALT's engineers review every project for design risk, manufacturability, and material selection before fabrication starts. We flag problems before they become failed parts, recommend alternatives when a design will cause issues, and bring domain expertise to every engagement — not just print operations.
US-based, fast turnaround
All design, simulation, scanning, and fabrication performed in Santa Barbara, CA. No overseas supply chain risk, no IP exposure from third-party processing, and domestic shipping timelines throughout. Most standard prototypes turn around in 24–48 hours from approved CAD.
Common questions.
What engineering teams, product developers, and research institutions ask most often about working with ALT.
Ready to start your
engineering project?
Tell us what you're building — ALT will scope it, quote it, and get started within one business day. Free consultation on every project.