Exergy
DESIGNS
Engineering Consultancy
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Trusted by Leading Engineering Teams Worldwide

Precision Engineering &
Advanced Simulation

Expert CFD, FEA, and multiphysics simulation services delivering validated, production-ready results for complex engineering challenges across aerospace, automotive, medical devices, and consumer electronics.

95+
Projects Delivered
14
Countries Served
$275K+
Engineering Output

Engineering Services

Comprehensive simulation and analysis capabilities for mission-critical engineering applications.

CFD & Thermal

CFD & Thermal Analysis

Advanced computational fluid dynamics for heat transfer, fluid flow, and thermal management optimization across complex geometries.

ANSYS Fluent • COMSOL
FEA & Structural

FEA & Structural Engineering

Finite element analysis for stress, strain, fatigue, and structural integrity validation under real-world loading conditions.

ANSYS Mechanical • SolidWorks
Magnetics

Electromagnetic Simulation

Precision electromagnetic field analysis for motors, transformers, actuators, and power electronics design optimization.

ANSYS Maxwell • COMSOL
Acoustics

Acoustics & NVH Analysis

Noise, vibration, and harshness simulation for product refinement, regulatory compliance, and enhanced user experience.

ANSYS Acoustics • COMSOL
CAD Design

CAD Design & Modeling

Professional 3D modeling, parametric design, and engineering documentation for manufacturing-ready product development.

SolidWorks Premium
DFM

Design for Manufacturing

Optimization of product designs for efficient manufacturing, reducing costs and improving production quality.

DFM Analysis • Cost Optimization

Cross-Industry Expertise

Delivering precision engineering solutions across diverse sectors with domain-specific knowledge.

Aerospace & Defense
Aerospace & Defense
Automotive
Automotive
Medical Devices
Medical Devices
Consumer Electronics
Consumer Electronics
Industrial Manufacturing
Industrial Manufacturing
Energy & Power
Energy & Power
Shuaib Badat

Shuaib Badat

Founder & Lead Engineer

A Professional Mechanical Design Engineer highly proficient in mechanical product development, concept rendering, and multiphysics simulation. With successful project delivery for clients across Switzerland, Germany, Australia, Canada, and the USA, Shuaib has led multidisciplinary engineering teams to develop pilot products for startups achieving remarkable success on the global business landscape. Specializing in turnkey product development, from idea inception through mass manufacture and logistics, with deep expertise in design for manufacturing, CFD analysis, thermal control, and energy optimization across HVAC, aerospace, medical equipment, fitness technology, and consumer electronics.

Projects
80+ Countries
Achievement
Top-Rated Plus
Career
CTO at EvansWerks
Location
Cape Town
$275K+
Annual Engineering Output
2,314
Hours Billed
95
Projects Delivered
$100K+
Upwork Earnings

Meet the Experts

A talented team of engineers and specialists dedicated to delivering precision engineering solutions for complex challenges.

Ebrahim Malek
Ebrahim Malek
Senior Electrical Engineer

Expert in electromagnetic simulation, power electronics, and electrical system design. Ebrahim brings extensive experience in motor design, transformer optimization, and high-voltage system analysis, delivering validated solutions for complex electrical engineering challenges.

Ismail Muttala
Ismail Muttala
Senior Engineer & DFM Specialist

Specializing in Design for Manufacturing optimization and production engineering. Ismail ensures designs are not only functional but also cost-effective and manufacturable at scale, bridging the gap between concept and production with precision.

Yusuf Mullah
Yusuf Mullah
Senior Mechanical Designer

Experienced mechanical designer with expertise in product design, CAD modeling, and design optimization. Yusuf brings precision and innovation to every project, ensuring designs are both functional and manufacturable with attention to every detail.

Yusuf Essa
Yusuf Essa
Business Strategist

Strategic business advisor with expertise in engineering operations, client acquisition, and project management. Yusuf drives growth initiatives and ensures alignment between technical excellence and business objectives for sustainable success.

Bogdan Dirlosan
Bogdan Dirlosan
Simulation Specialist

Expert in advanced simulation techniques and numerical analysis. Bogdan specializes in complex multiphysics problems, delivering accurate and validated results for mission-critical engineering applications across diverse industries.

What Our Clients Say

Trusted by innovative companies around the world for precision engineering solutions.

Shuaib was very professional throughout the whole process and response time was excellent! His expertise in fluids and heat transfer guided us into the right direction to achieve the results we needed. He also worked throughout the night, sometimes till 5AM, in order to meet our timelines. I highly recommend Shuaib and hope to work together again!
David Weisbach
We Build Machines
Visit Website
Shuaib was excellent - very diligent in working to meet my very restrictive requirements. Creative and smart solutions won the day!
Brian Astl
President at Lind Equipment
Visit Website
Our product had a persistent overheating issue three design firms couldn't solve. This engineer ran CFD thermal analysis, identified the root cause within hours, and proposed a fix we implemented immediately. Exceptional problem-solving skills and deep technical expertise.
Upwork Client
Mechanical Product Design
★★★★★ 5.0
Shuaib is very professional, skilled and creative design expert. His ideas are unique, robust and over achieved requirements. He is very knowledgeable in materials types, treatment and manufacturing limitations. Highly recommend for complex engineering projects.
Upwork Client
Windtunnel Design Project
★★★★★ 5.0
Shuaib is a highly detail orientated professional. He took on my project and delivered before the expected time, communication was clear and he exceeded my expectations. I highly recommend you work with him.
Upwork Client
Thermodynamics Simulation
★★★★★ 5.0
Collaborated on simple project: provides cutting edge information, very resourceful, great energy. You will learn and get more than just CAD models. Will collaborate further.
Upwork Client
Medical Device CAD Design
★★★★★ 5.0

Simulation Tools

Industry-standard software for accurate, validated results.

ANSYS Fluent
ANSYS Mechanical
ANSYS Maxwell
COMSOL Multiphysics
SolidWorks Premium
SolidWorks Flow Simulation
MATLAB Simulink

Software Development Services

Full-stack software engineering to complement our engineering expertise. From custom applications to automation tools, we build the digital infrastructure your business needs.

Web Applications

Custom web apps, dashboards, and portals built with modern frameworks. Responsive, performant, and scalable solutions tailored to your workflow.

React Next.js Node.js TypeScript

Mobile Apps

Cross-platform mobile applications for iOS and Android. Native performance with shared codebases for rapid deployment and cost efficiency.

React Native Flutter Firebase

API & Backend Systems

RESTful APIs, microservices, and backend architectures. Database design, cloud deployment, and integration with third-party services.

Python FastAPI PostgreSQL AWS

Automation & Tooling

Workflow automation, data pipelines, and custom engineering tools. Reduce manual work and streamline your processes with intelligent automation.

Python Selenium CI/CD

IoT & Embedded Software

Firmware development, sensor integration, and IoT platforms. Connect your physical products to the digital world with reliable embedded solutions.

C/C++ Arduino MQTT ESP32

AI & Data Solutions

Machine learning models, computer vision, and data analytics platforms. Turn your data into actionable insights with custom AI-powered tools.

TensorFlow PyTorch OpenCV

Schedule Your 1-on-1 Strategy Call

Get expert guidance on your engineering or software project. Book a dedicated consultation via Google Meet and receive a comprehensive product development quote and detailed process roadmap.

$60 per hour consultation
  • 1-hour Google Meet video call with our lead engineer
  • Custom product development quote tailored to your project scope
  • Detailed roadmap outlining every phase of the development process
  • Timeline, milestones, and deliverables breakdown
  • Syncs directly with your calendar for hassle-free scheduling

What You'll Receive After the Call

Development Quote
Itemized cost breakdown with transparent pricing
Process Roadmap
Step-by-step plan from concept to delivery
Project Timeline
Key milestones and expected delivery dates

Book Your Consultation

Select a convenient time slot for your 1-hour strategy call. The session will be held via Google Meet.

Schedule Now

Get Your Free Engineering Quote

Tell us about your project in under 2 minutes. Receive a detailed proposal within 24 hours.

1

What services do you need?

CFD CFD & Thermal
FEA FEA & Structural
Magnetics Magnetics
Acoustics Acoustics & NVH
CAD CAD Design
DFM DFM
2

How many Exergy engineers do you need?

1
Engineer(s)
3

Choose your engagement type

4

Tell us about your project

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