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.
Our Services
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Front end product development, research, concept generation, mechanical architecture, detailed design, rapid prototyping, DFM/DFA, design reviews and renders.
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Advanced CAD and surfacing, complex assemblies, tolerance analysis, Finite Element Analysis, engineering calculations, motors, sensors, electronics integration, and troubleshooting.
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Cross-functional product delivery, project planning and scheduling, milestone tracking, risk management, stakeholder communication, supplier coordination and manufacturing implementation
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Experienced with a wide suite of tools to ensure clear communication and projects progress tracking. These include Microsoft365 Suite, Google Workspace, Notion, Claude, Jira, Confluence, Asana, Miro, ClickUp, Slack, and multiple engineering PLM systems.
Meet The Team
…it’s a one man band
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.