Machine Design Services

Alexander & Associates annually supplies hundreds of thousands of hours of support services to a wide range of global clients, and has done so for more than 75 years. Our ability to grow in experience and promote from within has produced a support staff with an average of 15+ years of experience. With the range of support capabilities continually growing, A&A has the ability to deliver everything from conceptual ideas to final installed equipment to achieve the business objectives of our clients.

Project Definition

A&A is skilled in Scope Development, Manufacturing Process Considerations and Risk Identification. Through development of conceptual design options, A&A's staff of designers and engineers can identify, analyze, and make recommendations while carefully considering the impact to equipment operation, facilities/utilities, cost and schedule in an effort to provide best value to our clients.

Engineering & Design

A&A offers a comprehensive approach to equipment design and development services by means of several disciplines including Mechanical, Power & Control, Information Technology, and Fabrication. All designs are considered proprietary and all rights are owned by the client. Deliverables may include such items as (but not limited to):

  • Equipment/facility layouts and custom designed equipment in an array of 2D & 3D software
  • Calculations/FEA
  • Preparation of complete design packages including assemblies, detailed part fabrication drawings, and commercial part specifications for equipment bidding, purchase, and fabrication
  • Coordination of ancillary design considerations
  • Technical writing providing Engineering Instructions or Construction Work Plans for installation/equipment setup centerlines and Equipment Operation/Maintenance Manuals
  • Control System Design including Logic Development and Panel Design, Programming including PLC, Drive systems, and Operator Interface Applications
Equipment Shakedown, Installation and Training Support

As an added benefit to our clients, A&A's team of designers and engineers also provide support "after the design is complete" in various forms. Vendor equipment shakedown is a systematic approach to statically (without power) and dynamically (with power) demonstrate the machine assembly/set up is aligned to the "as designed" capabilities. During installation periods, A&A's team serve as a design liaison between the client and construction staff by providing design interpretation and issue resolution. Finally, A&A's technical team provide materials/instruction training for client's personnel on the set-up, operation and maintenance of the equipment.


  • Technical Support
  • Preparation of Testing Procedures and Benchmarks
  • Field Programming Support by Technical Specialists
  • System Trouble Shooting
  • Project specific training for operation and maintenance personnel
  • Application specific training for Drive, PLC and HMI systems
Mechanical Design

2D and 3D Mechanical DesignAlexander & Associates was started as a Mechanical Design firm over 65 years ago. Over those many years, Alexander & Associates has designed equipment ranging across a wide scope of industries. This vast experience allows our designers and engineers to bring a wealth of ideas and options to a client's design challenges.

Our expertise spans a variety of industry standard and custom/specialized machines including, but not limited to, High Speed Production Machines, Assembly and Packing Machines, Tooling, Fixtures, Gauges, and Remote Handling Systems.

Essential to success in today’s fast paced, ever changing and global design environment is a commitment to seek out and apply “cutting edge” technology. Alexander & Associates’ designers are continually exposed to new products and technologies and charged with evaluating how these advances may benefit a client’s project.

Our design teams are geared to meet our customer’s project needs with state of the art technologies. Personnel utilize the latest CAD systems with 3-D capabilities and associative geometry. Networking and trained in-house computer specialists insure that Alexander & Associates’ design teams have access to the fastest, latest and most complete design tools available.


  • High speed production equipment
  • R&D test stands and systems
  • Assembly and packaging applications
  • Converting applications (paper, film, etc.)
  • Material handling and conveying
  • Frame design, Drive Systems, Guarding
  • Mechanisms
  • Bearing selection and sizing
  • 2D, 3D, and solid modeling
  • Drafting and detailed design execution
  • Conceptual development
  • Prototype design
  • Modularity and quick changeover
  • Alignment planning and documentation
  • Inspection systems
  • Vendor Inspections and Vendor Acceptance Testing
  • Equipment installation support
  • Equipment Start-Up support
Power & Controls System Design

Testing Power and ControlsA&A’s skill set includes Machine Control Systems, PLC System Design, Variable Speed Drive and Servo System applications, Operator Interface Implementation, machine safety analysis, vision, system hardware including Control Panel Design, Hydraulic and Pneumatic System Design.

Alexander & Associates’ Power and Control department includes the electrical expertise for machine design and equipment integration applications. Alexander & Associates can provide the hardware and software needed to best suit your project. Hardware design is accomplished using the most current database driven software such as Promis·e® and AutoCad Electrical®. The database nature of the software packages allow for the efficient generation of support documentation for the fabrication of machines and control panels. Our designs comply with NEC, CE, UL508A, CSA and other applicable codes and regulations. Design packages can be assembled for the fabrication of a special machine or for the integration of equipment including special machines and standard equipment.

Our software engineers can provide designs tailored for your project. Expertise in a variety of PLC, Drives, Servo Systems, and HMI platforms allows the use of the right software for your needs, including Pack ML/Phase Manager based programs. Our HMI capabilities range from stand-alone systems to server based applications.

Several of our engineers are trained on state of the art servo and variable speed drive systems allowing us to offer a service few other design firms can provide.


  • Complete hardware design using AutoCad®, Autocad Electrical®, or Promis·e® software
  • Extensive machine flexibility utilizing variable speed AC, DC and servo drives
  • Experience with Rockwell: RSLOGIX® 5, 500, 5000, FACTORY TALK VIEW® (RSView), Studio 5000, RSNetWorx®, GML Commander®, Motion Analyzer®, DriveExecutive® and DriveExplorer®
  • Experience with SIEMENS: PCS7®
  • Experience with Giddings and Lewis® (G&L)
  • Experience with Wonderware®
  • Experience creating Human-Machine Interfaces (HMI) applications using various software
  • Programmable Controller applications emphasizing machine modularity, flexibility, and reliability
  • Equipment installation, Startup, and Shakedown Support available
  • Power systems designed for specific voltage and frequency requirements
  • Training documentation and presentations covering specific technologies and machine operations
  • Integration of various control platforms using ControlNet, DeviceNet, Ethernet/IP/CIP, SERCOS, ProfiBus, ProfiNet, and other industry standard communication technologies
  • SISTEMA (Safety Integrity Software Tool for the Evaluation of Machine Applications)
  • Cognex
Project Management

Project Management Progress MeetingSuccess of any project can be attributed, in part, to the level of detail given to its management. At Alexander & Associates, we have the capability of implementing sound project management work processes, using highly skilled resources on a wide array of project efforts and initiatives.

Every project effort can be broken into four primary phases: Definition, Execution, Construction, and Start-up. Within each of these phases, management will focus on Scope - description of effort and deliverables, Cost - funding strategy, spending curves, future cost projections (trending), and Schedule - duration of expectations including milestone check points.

At Alexander & Associates, Procurement & Purchasing professionals complement our experienced staff of Project Managers and Project Specialist by overseeing the equipment bidding process and expediting every order through delivery.

The goal of the Project Department at Alexander & Associates is to obtain the best value possible for our customer while ensuring their needs and project objectives are met.


  • Concept-to-Start Up project management capabilities
  • Experienced Project & Cost Management
  • Ensure proper level schedules are in place
  • Ensure that the business objectives are met
  • Project / Design Execution Management
  • Cost Controls - Trend & Status Reporting
  • Scheduling - Proactive management of the appropriate level execution team schedule with necessary level of detail to ensure effective delivery of project objectives/deliverables. Collaborate internally to manage resource planning/staffing to meet all client execution needs.
  • Procurement - Order origination/management within client and/or A&A Purchasing System(s), delivery status reporting/order expediting, Invoice review/reconciliation
  • Equipment Procurement
  • Specialized employees dedicated to preparation of equipment purchases including specifications, procedures, requests for quote and vendor inquiries, bid evaluations and vendor recommendations, purchase order issuance and status reporting, expediting and vendor follow-up during fabrication, delivery schedule control, inspections and acceptance tests (if required), shipping and delivery confirmation.
Safety Analysis & Validation


  • Machine Safety Training Program
    • Identify Hazards
    • Design solutions to mitigate them
    • Verify solutions to keep personnel safe
    • Understand current standards
  • A&A TUV certified Functional Safety Engineers (Machinery)
    • Risk Assessments
    • Develop/Write Safety Circuits
    • Design/Analyze Safety Circuits
    • Calculate Performance Levels or Safety Integrity Levels (SIL)
    • Write/verify Safety Validation documentation
    • Individuals trained/tested to ensure technical mastery
  • Foundation for documenting safety systems within a line or plant


  • Ensure latest standards* are met
  • Risk Assessment, mitigation, documentation
  • Prevent/reduce severity of injuries
  • Update outdated systems
  • Validate safety systems working as designed
  • Identify deficiencies/improving guarding
  • Calculate performance levels
  • Design/implement changes to make systems compliant

* OSHA 29 CFR 1910 requirements met by utilizing IEC-60204, IEC 62061 ISO 13849, and ISO-12100.


  • Collaborate with customer to understand needs
  • Perform analyses and calculations to identify and correct areas of non-compliance
  • Document safety systems utilizing A&A's standard Risk Assessment and Safety Validation processes
  • Certify that customer control systems and machine designs meet all safety requirements
  • By utilizing Functional Safety Engineers (TUV certified for machinery), A&A can meet all your safety needs
Full service technical solutions utilizing all of A&A's core competencies
  • Mechanical Design
  • P&C (Design & Programming)
  • Fabrication
  • Project Management/Procurement
Digital Systems Team


Our team is a group of resources who have expertise in multiple IT disciplines focused on improving the efficiency of plant operations.
Our specialties include:

  • Use of standard Microsoft Products for scheduling runs
  • Capturing Process Information
    • Historizing Control System Process Data
    • Capturing Quality and other production values
  • Providing near real time feedback to operations
    • Web forms for data entry
    • Web forms for feedback, charting, and basic alarming
  • Providing Quality Data Collection
    • Manual Collection
    • Automatic Collection from lab equipment
  • Providing Non-Production information systems such as inventory, document management, and others


  • Microsoft SharePoint/Flow/Power Apps
  • Microsoft SQL Server
  • Visual Studio
  • .Net (VB/C#/Javascript)
  • Microsoft Internet Information Services
  • Proficy Historian
  • Zebra Label Printing
  • 2D Datamatrix Identification


  • Collaborate with customer to understand needs
  • Options analysis to provide viable options
  • Prototype Solutions
  • Use agile development approach
  • Ensure customer needs are met
  • Provide system support
  • Document systems
Equipment Manufacturing

A&A Development's experience in prototyping and manufacturing, complimented by Alexander & Associates' technical design expertise, gives us a unique advantage in fulfilling a client's specific design/build and testing requirements.

We have the experience, resources and capabilities to handle a broad range of work. A&A's long history of special machine design complimented by our build capabilities enables us to handle everything from a single part fabrication to turnkey design/build and run-off of custom machinery. We are recognized for our attention to detail and quality.

Equipment Overview & Capabilities:

  • Milling:
    • Doosan 3 axis VMC - 60x30x30 travels
    • Haas VF-3 -4 axis VMC - 40x20x20 travels
      • Machine is equipped with a Haas HRT210 rotary axis w/tailstock
    • Southwest Industries LPM 3 axis VMC - 30x18x18 travels
    • Southwest Industries TRAK 3 axis Bed Mill - 30x18x18 travels
    • Southwest Industries TRAK 2 axis Knee Mill - 30x18x18 travles
  • Turning:
    • Southwest Industries 1845 CNC lathe with a 4-position tool turret
    • Royal Gap Bed Engine Lathe - manual machine - 13x40 capacity
    • Metosa Manual Engine Lathe - manual machine - 10x60 capacity
  • Sawing:
    • Cosen C-510MNC - Automatic Horizontal Mitering Bandsaw - 14" Dia. capacity
    • KMT - Manual Horizontal Mitering Bandsaw - 12" Dia. capacity
    • Drake - VH24 Vertical Blade Bandsaw
  • Shape Cutting:
    • 5 Axis Hypertherm Plasma Shape Cutting Machine
      • 400 Amp - Cutting capacity of up to 2" thick mild steel plate
  • Forming:
    • 230 Ton Cincinnati Auto-Shape Press Brake - 10' forming between frames
    • 90 Ton Cincinnati Auto-Form Press Brake - 6' forming between frames
    • 75 Ton DAKE brand electro-hydraulic press
    • 120 Ton Piranha Ironworker with dies and brake attachments
    • Ineco programmable Rotary Die Bending machine
    • Ercolina mandrel style 3 axis programmable Rotary Die Bending Machine
      • 10' long mandrel table
  • Welding:
    • MIG/TIG welding on carbon steel, stainless steel, aluminum or other alloy materials
      • Miller Dynasty 700 & Miller Dynasty 350 for TIG & constant current applications - Pulse capability and Waveform Adjustable
      • Spray Transfer .045 wire GMAW for heavy plate applications
      • Wire fed spool gun for thick aluminum or heavy deposition aluminum welding
      • Miller XMT machines running GMAW & .035 wire for standard MIG welding applications
      • 500 Amp Miller FCAW machine for structural applications
      • Carbon Arc Gouging capabilities up to a 3/8” diameter rod
    • WeldPro 360 boom welding unit covers 56’ diameter area for larger weldments
      • Weld quality monitoring with reports for weld spec. compliance
    • Capacitor Discharge Stud Welding capabilities to 3/8” diameter
    • Ensitech Tig-Brush - electro-chemical stainless-steel weld cleaning & passivation system
    • Demmeler precision welding / set-up tables & associated tooling
    • Weldsale brand welding / fixturing table – 10’x5’ table-top
  • Material Handling:
    • 5 Workstation Jib Cranes servicing all machining areas
    • 5 Fork trucks with lifting capabilities of up to 36,000 pounds
      • Roll clamp attachment capable of handling up to a 90” diameter wound roll
    • Caldwell Spreader / Lifting Beams up to 10-ton capacity and up to 22’ in length
    • 5-ton Bridge Crane servicing our assembly area
      • 40-foot span with roughly 12 feet of lift height
      • Dual 3-ton hoists on a common I-Beam
    • 10-ton Bridge Crane servicing 1/3rd of our manufacturing floorspace
      • 60-foot span with 24 feet of lift height
  • Infrastructure / Support Equipment:
    • Heavy distributed power throughout the shop area / 480V / 1,600 amp
    • (2) 25HP Quincy compressors coupled to a refrigerated compressed air dryer
    • 1000 gallons of compressed air storage
    • 4’ x 4’ granite surface plate and ancillary metrology measuring equipment
    • ERP system for shop process management, part tracking, job scheduling and estimating
    • 3D modeling software at all machine stations for generating machine code from solid models
    • Inventor HSM & BobCAD G-Code software available for machine programming
Equipment & Process Development

During research and development efforts, once the design is complete and the equipment has been manufactured and assembled, then the effort of fine-tuning the efficiency of the equipment and establishing operational process centerlines begins. The Alexander & Associates Development facility is uniquely equipped to support design/build efforts due to the availability of staffing resources from the various disciplines of the A&A organization. These skilled resources have vast experience and knowledge of testing, analysis of test result data, and process development for effectively delivering complete projects.

The Development facility infrastructure offers 30,000 square feet of manufacturing space with high bay (30’) ceilings. Ample 480V/3 phase power, compressed air and utilities necessary for running equipment is readily available for use. Temporary tie-ins to these systems for testing/development purposes. With in-house support personnel and fabricating/manufacturing machinery, A&A is capable of handling any need that should arise. For our client’s convenience, the facility provides secured wireless internet connection as well as office space and associated amenities can be provided for client use during testing/development and provisions for disposal of project related materials (test products, raw materials, etc.). The facility is a secure location with limited access to outside personnel during normal business hours. A&A can also accommodate special requests should the project require special security considerations for confidentiality purposes, such as tarping/panels around the equipment. Upon completion of the development effort, design resources can be made available at the Development facility for breakdown/match-marking of equipment for shipping and preparation for subsequent reinstallation at the client’s facility.

Prototype Equipment/Proof of Principle

Prototpye 3D Printed DesignFrom initial concept through completed project, we provide you with the technical expertise, fabrication skills, and final testing to help to "find better ways" to meet your project goals.

Alexander & Associates Development specializes in the production of high quality prototype equipment. Our focus is to provide unique solutions for development projects to efficiently and cost effectively meet the client's objectives. We can manufacture everything from specific low-investment parts for testing to fabricate, assemble and test complete machines.


  • Parts Design and Fabrication
  • Implementation of Rapid Prototyping or low-investment equipment for testing opportunities
  • Design capabilities with extensive development experience
  • Flexibility to meet the needs of the client and therefore, react more quickly to modifications and changes
Equipment Procurement

Specialized employees dedicated to preparation of equipment purchases including specifications, procedures, requests for quote and vendor inquiries, bid evaluations and vendor recommendations, purchase order issuance and status reporting, expediting and vendor follow-up during fabrication, delivery schedule control, inspections and acceptance tests (if required), shipping and delivery confirmation.

Technical Writing

To compliment Alexander & Associates' design, fabrication and development support is our ability to supply our client's technical documentation needs. Based on the client's documentation needs, our team of design personnel is versed in providing technical documents such as:

  • Risk Assessments (safety)
  • Equipment Test Plans
  • Equipment Shakedown Plans
  • Vendor Acceptance Test Plans
  • Engineering Instructions or Construction Work plans for equipment installation
  • Construction and Shakedown Checklists
  • Equipment Start-Up Plans
  • Equipment Operation Manuals
  • Equipment Maintenance Manuals
  • Recommended Spares List
Design Software Platforms

Alexander & Associates has a wealth of Design Software platforms at our disposal. Our experienced and dedicated team of designers bring a significant diversity of backgrounds to a client's technical needs.

Alexander & Associates has consistently achieved results of excellence across a broad segment of industry. Projects are undertaken and completed by a permanent staff of professionals committed both individually and collectively to understanding and serving the needs of our clients. Whether the project ranges from redraws and as-built efforts to special machine design and prototype development, we have the staff, experience and design/CAD systems to get the job done.

Solid Modeling based CAD packages are at the core of Alexander & Associates' CAD expertise. This in-depth experience allows for rapid project concept to completion times. If your project requires 3-D modeling, prototyping or machine functionality design verification, we can readily handle these task with confidence. Software Systems are constantly upgraded to stay at the cutting edge of technology. Don't see your design platform of choice in the list below, no problem. Please consult with our design team for availability and/or options to meet your design needs.


  • SolidEdge®
  • SolidWorks®
  • Autodesk® Inventor® Nastran®
  • AutoCAD®
  • MicroStation®
  • MS Platform - Word, Excel, Project
  • Touchplan
  • Wonderware Historian
  • Proficy Historian
  • AutoCAD® / AutoCAD Electrical®
  • Bentley Promis·e®
  • Friedhelm LOH Group EPLAN®
  • Rockwell® Software
  • Rockwell® Automation
  • Giddings and Lewis® (G&L)
  • SISTEMA (Safety Integrity Software Tool for the Evaluation of Machine Applications)
  • Cognex In-Sight®
  • Robotics Fanuc®

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