A selection of engineering projects completed for clients across mining, heavy industry, infrastructure, and defence. Client details are anonymised; technical outcomes are real. All work completed by Andrew Crutchley, Chartered Professional Engineer.
FEA-based structural assessment of a large mill reline machine boom arm and chassis under maximum operational loading. Analysis identified a stress concentration requiring a weld detail change, avoiding a potential in-service failure.
Design and FEA-based Grade 2 certification of a rollover protective structure for a military light vehicle. Full certification package produced to ISO 3471 and WorkSafe NZ requirements, suitable for formal procurement submission.
Static and fatigue FEA of a hydro dam control gate structure under normal operating and flood-event loading conditions. Analysis supported a refurbishment decision extending the structure's operational life by an estimated 25 years.
Fatigue life assessment of a high-cycle conveyor frame experiencing cracking at welded joints. FEA identified the critical failure mode and guided a weld toe improvement programme that eliminated repeat cracking in service.
Independent FEA review of a falling object protective structure roof panel submitted by an OEM. The review identified a sub-standard weld specification and provided recommendations to bring the structure into compliance with ISO 8083.
Structural FEA of a weapon system mounting bracket on a military platform, assessing static and dynamic loading including muzzle impulse. Analysis confirmed structural adequacy and identified an optimal weld specification at the critical joint.
3D scanning of an ageing structural frame where original drawings were unavailable. The point cloud was processed into a precise CAD model in Autodesk Inventor, which then served as the geometry input for an ANSYS FEA structural assessment ahead of a planned load increase.
3D scanning of a worn OEM drive flange — no longer in production — to reverse engineer a replacement. The scan captured actual worn geometry; nominal dimensions were recovered by analysis and comparison with mating components, producing a full manufacturing drawing package for local remanufacture.
Every engagement starts with a direct conversation. Tell Andrew about your project and he'll respond within one business day.