Stephen Wright
CEng MIMechE MEng DIS
About Me
I’m a Chartered Senior Mechanical Engineer currently working at DCA Design, a leading product design consultancy based in the UK. From conceptualizing new products and technologies to delivering detailed designs for mass production, I work on problems that require a hybrid of skills. This includes Design, Engineering, Software, Electronics, and a range of Creative Technologies.
This website helps me to catalog interesting things I learn from projects that I work on in my spare time. Unfortunately, I can’t share many details about my professional work, however, I can show a taste of some of the public projects I have worked on. If you would like to ask questions, provide hints or even criticism feel free to contact me here.
All image credits go to DCA, links to project pages are provided below.
DCA Design International (2014–Present) Selected projects completed during my time at DCA.
Client: Rolls-Royce & Cranefield University
Description: In 2019 we designed and built a full-size flight simulator for Rolls-Royce, in collaboration with Cranfield University, to test future flight systems, cockpit interfaces, and emerging aviation technologies. Now in regular use at the Aerospace Integration Research Centre (AIRC) at Cranfield, the simulator was awarded the iF Design Award in 2021. It provides a flexible, interactive environment for pilots, engineers, and designers to explore next-generation aviation technologies such as hybrid-electric propulsion, autonomous systems, and advanced human-machine interfaces. The “FSS” plays a key role in shaping sustainable, safer, and more collaborative flight systems for the future.
Skills: Mechanical Engineering, Electronics Hardware, Interaction Design, Simulation/Finite Element Analysis (FEA)
Client: Honeywell
Description: A world-first, groundbreaking self-test technology developed in collaboration with Honeywell, enabling smoke and heat fire detectors to be tested remotely using a compact, integrated module. As the first UL-approved self-testing smoke detector, this patented technology generates artificial smoke within the detector footprint to verify performance automatically, removing the need for manual testing and enabling safer, more efficient maintenance in hard-to-access spaces. Now launched globally across Honeywell’s detector portfolio, it represents a major advancement in fire safety and was awarded the Gold Edison Award for Innovation in 2023.
Skills: Product Design, Mechanical Engineering, Electronics Hardware, Safety Systems, Prototyping, Design for Manufacture, Testing & Validation, High-Volume Production.
The technology enables smoke and heat fire detectors to be tested remotely using a compact module that fits inside existing detectors. The module generates artificial smoke to periodically test the detector’s performance, improving inspections by eliminating barriers to testing and maintenance, including locked rooms, high ceilings, and hard-to-access spaces, ultimately creating safer building environments for people.
Client: Bentley Motors
Description: A complex electromechanical prototype developed in collaboration with Bentley, designed to explore the use of Artificial Intelligence in enhancing in-car comfort and user interaction. This physical AI interface incorporated custom electronics and three custom PCBs, alongside 244 addressable LEDs and 78 motors. The custom hardware and software autonomously adjust comfort parameters based on user preferences and environmental factors, pushing the boundaries of automotive user experience. Presented at the 14th International ACM Conference on Automotive User Interfaces, this experimental prototype merged AI with tactile interaction, fostering trust between the user and the system, and laying the foundation for future AI-powered automotive interaction solutions.
Skills: Mechanical Engineering, Mechatronics, Software Development, AI & Machine Learning, Industrial Design, Prototyping, Human Factors & Usability, Systems Engineering, UX/UI
Technical Innovation, Interface Design, Prototyping, Production Support, Mechanical Engineering, Electronics and Software
Client: Five AI (Acquired by Bosch in 2022)
Description:A cutting-edge project developed in collaboration with Five AI, focused on creating AI systems for autonomous vehicles. Designed and built the sensor enclosure mounted on the roof of the fleet of vehicles, providing a robust and aerodynamic housing for the sensor suite.
Skills: Mechanical Engineering, Sensor Integration, Software Development, Autonomous Systems, Deep Learning, Robotics, Prototyping, Systems Engineering
Client: D-Fly Ltd
Description: The world’s first “Hyper Scooter,” developed from initial concepts to fully functional prototypes. The design integrated a wide range of advanced technologies, including motor control systems, in-wheel motor designs, optics and lighting, acoustics and speaker systems, and composite materials. Additionally, the project involved the development of the scooter’s battery and electrical systems, ensuring optimized performance and efficiency. A key innovation is the patent-pending custom suspension system, “Full-Tilt technology,” which integrates both yaw and tilt rider controls with a double wishbone suspension. Extensive Finite Element Analysis (FEA), prototyping, and testing were conducted to refine the design and maximize performance, resulting in a high-performance, cutting-edge scooter that pushes the boundaries of urban mobility.
Skills: Mechanical Engineering, Motor Control Systems, Suspension Design, Optics & Lighting, Acoustics & Speaker Design, Composites, Battery Systems, Electrical Systems, Control Systems, FEA, Prototyping, Testing
Client: Dräger Safety AG & Co.KGaA
Description: An entry-level particulate Powered Air-Purifying Respirator (PAPR) designed to deliver reliable respiratory protection while prioritizing ease of use, compactness, and cleanability. Engineered for simplicity and durability, the unit features an intuitive user interface and service-friendly construction for straightforward maintenance. Its robust design allows cleaning in industrial dishwashers, enabling efficient and hygienic processing of multiple devices—ideal for demanding safety and industrial environments. Awarded an iF Design award in 2025.
Skills: Product Design, Mechanical Engineering, Safety Equipment Design, User-Centered Design, Usability Engineering, Prototyping, Testing, Industrial Design
Client: Sanofi
Description: The ‘3D Pen’ is a disposable pen injector designed to improve the self-injection experience for diabetes patients. It delivers variable doses up to 120 units in one-unit increments, using a spring-powered mechanism for automatic, comfortable injection without requiring button extension. An intuitive sliding gauge and audible click provide clear feedback on dose selection and delivery progress.
Skills: Medical Device Design, Mechanical Engineering, Human Factors, Prototyping, Industrial Design
Ultra Electronics Sonar Systems (2012)
Selected project completed during my time at Ultra Electronics.
Ultra Electronics | SeaFox
Semi-autonomous disposal of naval mines – Unmanned Underwater Drone
