Reading log · logged, not billed0:00
    Trusted by leading engineering teams worldwide

    From concept to manufacture, verified at every step

    Precision engineering consultancy with built-in accountability. Every hour tracked. Every deliverable audited.

    Scroll to assemble the part

    115+projects
    14+countries
    2,714hours tracked
    100%auditable
    What we solve

    One part, four services

    Design work · 1 of 4

    Design work

    From a sketch, photo or idea to a precise, manufacturable 3D design: concepts, CAD models and assemblies ready to build.

    CADDFM
    SolidWorks · NX · Fusion 360
    Structural analysis · 2 of 4

    Engineering simulation

    If it can be simulated, we simulate it: fluids, heat, structures, motors, acoustics. We turn “will it work?” into a validated, visual answer.

    FEASimulationMultiphysics
    ANSYS · Abaqus · COMSOL
    Flow and thermal · 3 of 4

    Surface heat maps

    See exactly where your product runs hot. We map temperature, pressure and stress straight onto the 3D surface so problem spots jump out at a glance, before you build.

    CFDThermal
    ANSYS Fluent · OpenFOAM · Flow Simulation
    Drawings · 4 of 4

    Mechanical drawings

    Production-ready 2D drawings a manufacturer can build from first time: full dimensions, tolerances, GD&T and bill of materials.

    DrawingsGD&T
    ISO / ASME · DWG / PDF
    Where we work

    Industries we serve

    We have delivered across these sectors, but good engineering travels. If your field is not on the list, the physics still applies.

    AerospaceAutomotive & EVMedical devicesConsumer electronicsPower electronicsMotors & drivesHVAC & refrigerationIndustrial equipmentManufacturingConsumer productsEnergy & cleantechRobotics & automation
    How we deliver

    The Exergy method

    Every project follows a four-phase process, from discovery to handoff, verified at every step. Scroll sideways through it.

    Phase 01 · Scope

    Discovery and requirements alignment

    We assess feasibility, define deliverables, and agree on timelines before any work begins.

    RequirementsFeasibilityTimeline
    Led by Shuaib · Yusuf E.
    Phase 02 · Design

    Engineering and simulation

    Your project moves through CAD modelling, multiphysics analysis, and iterative optimisation.

    CADSimulationDFM review
    Led by Shuaib, lead engineer
    Phase 03 · Verify

    Quality checks and accountability

    Every deliverable goes through peer review and Exergy Track audit before reaching you.

    Peer reviewQCTrack audit
    Led by Shuaib
    Phase 04 · Deliver

    Handoff and support

    Complete documentation package with revision support and lessons captured for continuous improvement.

    DocumentationHandoffRevisions
    Led by Yusuf E. · Sulaymaan

    48 h to a scoped proposal. Then the work is verified, hour by hour.

    The assembled heat sink, fan and motor, drawn The same part as a thermal contour analysis
    Fig. 2 · the same part, after analysis
    Why clients trust us

    Verified, not promised

    Every project is monitored through Exergy Track, our internal verification system that captures work activity, enforces quality checks, and ensures full transparency.

    0hours tracked
    0+projects verified
    100%auditable
    0+countries

    Capture, verify, review, report. Weekly cost and activity reporting, fully auditable.

    The platform

    See Exergy Track in action

    One platform to onboard engineers, verify every hour, and manage projects with AI-powered insights.

    Exergy Track sign-in screen
    Step 01 · Get access

    Sign in or request access

    Get started in under 24 hours. Sign in with Google SSO or email, configure your workspace, and your team is ready to go.

    • Google SSO or email/password authentication
    • Desktop tracker app for engineers
    • Pre-configured workspace and billing
    Exergy Track team management
    Step 02 · Set up team

    Build and manage your team

    Add engineers with role-based access, set hourly rates, and track team activity and costs in real time.

    • Role-based access: admin and freelancer
    • Configurable hourly rates per engineer
    • Weekly cost and activity reporting
    Exergy Track time review
    Step 03 · Monitor work

    Review every work block

    See exactly what your engineers are working on. Review screenshots, approve time blocks, and monitor activity levels across your entire team.

    • Screenshot grid with approval controls
    • Activity percentage per 10-minute block
    • Live timer with screenshot preview
    Exergy Track AI project room
    Step 04 · AI project room

    AI-powered project intelligence

    Ask questions about any project and get instant answers drawn from time entries, meeting transcripts, and team activity.

    • Natural-language project queries
    • Fireflies meeting transcript sync
    • Action items and recent screenshots

    Available for Exergy Studio clients. Onboarding takes less than 24 hours.

    Who delivers

    Leadership and delivery

    Every engagement is led by Shuaib Badat, who is personally accountable for delivery, and resourced by a vetted network of specialist engineers we scale to each project. You always know who owns your outcome.

    Shuaib Badat

    Shuaib Badat

    Founder / lead engineer

    A professional mechanical design engineer with expertise in CFD, thermal analysis, and turnkey product development. Projects delivered across 14 countries. Top-Rated Plus on Upwork.

    [email protected]
    Yusuf Essa

    Yusuf Essa

    Project manager

    Project manager coordinating engineering operations, client communication, and on-time delivery across every engagement.

    [email protected]
    Sulaymaan Desai

    Sulaymaan Desai

    HR and project coordination

    Coordinates people, scheduling, and project logistics so every engagement runs smoothly from kickoff to handover.

    [email protected]
    The network

    Specialist engineers, per project

    CFD, FEA, electromagnetics, acoustics, CAD and DFM, brought onto the projects that fit their strengths, tracked and paid weekly through Exergy Track. We onboard selectively and keep a waitlist.

    Apply to join
    Proven results

    What our clients say

    Top-Rated Plus on Upwork100% job success$275K+ annual output
    “Exergy was very professional throughout the whole process and response time was excellent! Their expertise in fluids and heat transfer guided us in the right direction to achieve the results we needed. The team also worked throughout the night, sometimes till 5AM, to meet our timelines. I highly recommend Exergy and hope to work together again!”
    David Weisbach We Build Machines webuildmachines.us
    “Exergy was excellent, very diligent in working to meet my very restrictive requirements. Creative and smart solutions won the day!”
    Brian Astl President, Lind Equipment lindequipment.net
    “Our product had a persistent overheating issue three design firms couldn't solve. Exergy ran CFD thermal analysis, identified the root cause within hours, and proposed a fix we implemented immediately. Exceptional problem-solving and deep technical expertise.”
    Upwork client Mechanical product design 5.0 / 5
    “Exergy is a highly professional, skilled and creative design partner. Their ideas are unique, robust and over-achieved requirements. The team is very knowledgeable in material types, treatment and manufacturing limitations. Highly recommend for complex engineering projects.”
    Kadronics Wind-tunnel design kadronics.com
    “Exergy is a highly detail-orientated team. They took on my project and delivered before the expected time, communication was clear and they exceeded my expectations. I highly recommend you work with them.”
    Upwork client Thermodynamics simulation 5.0 / 5
    “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 / 5

    Six of ninety-five. The rest are on the record with their clients.

    Ready to start?

    Start your project

    Tell us your goal. We work out exactly what you need and scope it within 48 hours.

    Q3 2026 · 6 of 10 project slots open

    0 / 9sections read
    0:00time on page, measured
    0.00billed. Hours on your project are logged the same way.