Introduction
Machine building is in our DNA. For decades, we have designed one-off special machines: from welding jigs to complete production lines. Plenty of challenges, but our engineers thrive right at the edge of the unknown. Today, we no longer operate safely on land alone; we have also proven ourselves at sea, where we feel just as much at home.
For decades we designed one-off special machines for welding window frames, rack beams, fuel tanks, truck silencers, fuel injection systems, office cabinets, IBCs, floor grates, sprinkler pipes and more. Later, we added standard welding cells with fixtures for bumpers, seats, body parts and electrical enclosures. Joining technology, particularly welding, was at the core.
No machine can operate without handling, transport and assembly. That is why we expanded into logistics applications: machines that fill crates, move components or assemble submodules. The step toward offshore engineering turned out to be smaller than expected, but the challenges significantly greater. And that is exactly where our engineers are at their best.
At sea, everything is different
A ship at sea is a world of its own. The sea is beautiful, yet unforgiving. It quickly teaches you that small mistakes can have major consequences. The environment constantly challenges you: motion, waves, wind, corrosion, fatigue and temperature fluctuations. Everything is more extreme. Scale also plays a crucial role: everything becomes larger, heavier and more complex. Where on land we are used to bolts up to M16, offshore machine components often start at M20 and above. Lifting is not done with a colleague and a jack, but with slings, shackles and lifting eyes.
This increase in scale introduces additional design challenges. Weight and dimensions influence not only transport and installation, but also stability and dynamic loading. At sea, the platform is in continuous motion, meaning machines and systems are constantly subjected to additional forces. Even gravity "feels" different due to the vessel’s movements. This requires robust designs capable of enduring a long lifecycle under harsh conditions.
Extreme conditions demand survival design principles
Design thinking changes offshore: machines must be survival-proof. That means robustness, redundancy and the ability to perform repairs as easily as possible. It is not about "working when everything goes perfectly," but about "working when everything goes wrong." That requires different design principles.
Extreme offshore conditions make safety, robustness and self-reliance fundamental values. In offshore machine building, we continuously ask ourselves:
- What can go wrong?
- How can we prevent it? And what if it happens anyway?
- If this module cannot be repaired, do we have a backup or alternative?
The design process is therefore often built on a survival mentality: everything must withstand unexpected situations, and maintenance or repair must be possible on site, often under challenging circumstances.
This survival mindset translates into design principles such as:
- Redundancy in critical systems.
- Accessible components that can be replaced quickly.
- Mechanisms that can be released using simple tools.
- Corrosion protection through coatings, material selection and smart lubrication systems.
- Sea fastening and strong fixations capable of withstanding motion and vibration.
Offshore machine building is therefore characterized by simplicity and robustness, combined with scenario-based thinking and fail-safe measures.
Assembly and handling at sea
On land, machines are typically designed for production in controlled environments. At sea, this is far less predictable. Nevertheless, demand for specialist vessels functioning as "factories at sea" is increasing. Examples include:
- Pipelines welded together on board the vessel.
- Sensor modules clamped onto cables and later dismantled.
- Flexible fall pipes assembled from separate segments stored on board.
- Manipulators assembling specific pipe sections from various components.
This requires dedicated handling solutions: modular systems, simple locking mechanisms and accessible interfaces. The starting point is always safe, efficient and reliable assembly, even in a dynamic environment.
Robustness versus flexibility
A recurring design challenge in offshore machine building is balancing robustness and flexibility. Consider a crank-and-connecting-rod mechanism: a reliable mechanical component that always performs the same motion. This makes inspection and maintenance easier, without the need for extensive manuals. But what if more flexibility is required, such as variable speed, adjustable stroke lengths or a different mechanical configuration?
In such cases, we increasingly shift toward servo technology. Mechanical systems become simpler, while control systems and intelligence grow more advanced. What used to be solved mechanically with a cam disc must now rely on reliable motor control. This requires close collaboration between mechanical engineers and software programmers.
That collaboration is embedded in our DNA. In special machine building, it often feels like creating a prototype without a trial period: it must function correctly from day one. This demands tight coordination between design, construction and commissioning.
People and safety
At sea, safety is always the top priority. Machines must not only be robust, but also safe to operate. Controls must be intuitive, maintenance must be performed without risk and physical strain on the crew must be minimized.
We therefore design with generous safety factors wherever possible. We comply with strict international standards, yet consciously set the bar even higher: simplicity, reliability and scenario-proof design are our standard. Robustness always comes first.
Materials and maintenance concepts play a crucial role. Corrosion is a constant enemy at sea, which is why we work with coatings, special alloys, watertight seals and smart lubrication systems. Because time and resources for maintenance are limited, we always design with accessibility and simplicity in mind. Components must be easy to inspect, maintain or replace. Maintenance strategies are not an afterthought; they are an integral part of the design.
Digital prototypes and the use of VR
This focus on safety and robustness creates room for innovation. In several offshore projects, we use virtual reality and digital prototypes to test and optimize designs. With VR headsets, engineers and stakeholders can walk through a full-scale digital environment to verify process clarity, workspace layout and service accessibility.
VR also helps determine and validate walkways, escape routes, cable routing and ventilation channels. The digital model becomes a powerful tool for identifying and evaluating safety risks at an early stage. In addition, we use digital prototypes and simulations to test designs under realistic conditions. These methods allow us to identify bottlenecks early, prevent design errors and guarantee feasibility. As a result, offshore machines do not only work on paper, but withstand the most extreme real-world conditions.
How MechDes sets itself apart
With more than 30 years of experience in machine building on land and 20 years of offshore engineering experience, we have built a strong foundation. Our engineers deal daily with scaling up, extreme robustness, lifecycle-enhancing decisions and close integration between mechanics and control systems.
We translate this expertise into designs that are not only technically sound, but also scenario-driven and tested within the maritime context. With every design, we ask: what can go wrong, how do we prevent it, how do we solve it, and what is our alternative? The result is a combination of knowledge, practical experience and creative engineering.
The outcome: machines that do not merely function, but endure under the most challenging conditions. Offshore machine building represents mechanical engineering at its best: reliable, intelligent and practical.
Water shapes the Netherlands, just as innovation shapes us. The Dutch cannot live without water, and neither can we.
