Idea in mind,
Product in hand.
Services
Hardware product design, mechanical engineering & project management.
D.Allen Design turns ambitious hardware ideas into practical, production-ready products — from early concepts and mechanical architecture through prototyping, validation and manufacturing.
-
Front end product development, research, concept generation, mechanical architecture, detailed design, rapid prototyping, DFM/DFA, design reviews and renders.
-
Advanced CAD and surfacing, complex assemblies, tolerance analysis, Finite Element Analysis, engineering calculations, motors, sensors, electronics integration, and troubleshooting.
-
Cross-functional product delivery, project planning and scheduling, milestone tracking, risk management, stakeholder communication, supplier coordination and manufacturing implementation
-
Your design is stuck between prototype, validation and manufacture.
Your product-development team is overloaded or temporarily under-resourced.
A mechanical or electromechanical challenge needs focused ownership.
A production, quality or throughput constraint needs a practical engineering solution.
Need help getting your idea from a concept to a physical product — in your hand, ready to go to market?
Meet the Founder.
I’m Toby McConnell, a product design engineer and the founder of D.Allen Design. I help turn ambitious hardware ideas into practical, production-ready products.
My experience spans the full product development lifecycle —from early concepts and mechanical architecture through prototyping, validation, manufacturing and market launch.
Alongside hands-on engineering, I bring strong project management experience. I have led cross-functional product delivery, managed technical pilot programmes, and coordinated schedules, stakeholders, suppliers, contractors and overseas manufacturers. For larger or more demanding projects, I can also bring together and coordinate a trusted team of designers, engineers and other specialists, providing clients with the right expertise while maintaining clear technical direction and a single point of contact.
I enjoy working collaboratively with clients, designers, engineers across a range of disciplines, manufacturers and suppliers to create thoughtful, functional products that are genuinely ready to go to market.