Introduction
Sustainability is no longer a trend. In modern machine building, it is a fundamental starting point. At MechDes, however, it goes beyond simply "designing green." It is about using energy, materials, and space intelligently, without compromising performance. In this way, we design machines that are not only reliable and efficient, but also contribute to a more sustainable world.
Smart design becomes far more interesting and challenging for an engineer when motion is involved. By analyzing and understanding movements, we can save energy, reduce wear, and design machines that last longer. These insights form the core of our design philosophy: Less is More.
Less is More: minimal means, maximum impact
The Less is More principle forms the foundation of our approach. It demands sharp engineering choices, thorough calculations, and intensive testing. Everything that can be eliminated cannot cause a malfunction, and reducing complexity and material saves costs. The result is smarter, lighter, and more efficient designs with a longer service life. This vision has long been championed by our Managing Director, Henk van Ommeren, and has become inseparably linked to our entire engineering process.
Less is More means in practice:
- No unnecessary mass or components
- No unnecessary complexity
- Achieving functionality with minimal effort, always validated and tested
This philosophy is visible in all our projects: from small components to complete special machines in automation, lifting & handling, infrastructure, and offshore machine building. By critically evaluating every component and every movement, we create machines that achieve more with less, while also being more sustainable and cost-efficient for our clients.
Using energy intelligently
A sustainable machine starts with its energy concept. We always ask: Where does the energy come from, where does it go, and where can we retain or recover it?
Examples from our projects illustrate this approach:
- From pneumatic to electric: highly dynamic applications with long strokes are often more efficient electrically, as compressed air consumes significant energy during large movements. Shorter strokes with low dynamics that require continuous force may be more advantageous with compressed air or hydraulics. The Total Cost of Ownership (TCO) and maintenance requirements must always be considered in this balance.
- Vacuum ejectors versus vacuum pumps: a relatively small modification, such as replacing an ejector with a more efficient pump, can significantly reduce energy consumption in specific situations.
- Smart braking and combining movements: by combining movements or applying counterweights in slow-moving applications such as locks, sluices, and bridges, or in dynamic applications with robots, energy consumption can be reduced efficiently.
- Energy recovery in motion: together with partners, we apply systems that recover kinetic energy when braking rotating masses. Instead of being lost, the energy is stored within the system and reused via an accumulator.
Recovering energy where you least expect it
Regeneration is a recurring theme for us. In special machines, transport systems, robot arms with End of Arm Tools (EOAT), and offshore machine building, kinetic energy is temporarily stored and reused during acceleration or lifting.
A concrete example is the use of supercapacitors. These absorb peak electrical power demand, preventing peak loads from impacting the main supply unit. By placing supercapacitors decentrally, the entire electrical infrastructure can be downsized. In advanced applications, we have enabled multiple actuators to exchange electrical peak power and, based on calculations, concluded that the total connected load of a system can be drastically reduced. This result is achieved because all components are designed integrally and aligned with one another.
"Our challenge is to minimize energy losses in machines. We continuously test this through simulations and keep optimizing."
Lighter and smarter: less mass, less energy
Another pillar of sustainability is material selection and structural design. Through conscious choices in materials and production methods, we continuously evaluate how constructions can be made lighter and more energy-efficient.
- Materials: which materials are suitable for which application? Are renewable or recycled materials viable?
- Production methods: which method minimizes waste and energy consumption?
- Design choices: how can we eliminate material without losing functionality?
The Less is More principle prevents over-engineering, preserving performance while making the design more efficient. Less mass means lower energy requirements, reduced wear, and often cost savings in production.
A practical example: when integrally designing End of Arm Tools (EOAT) with a robot, one additional kilogram in the EOAT can trigger a chain reaction. Increased loads result in heavier geometry, larger bearings, and higher required power, leading to greater energy consumption and higher costs. By critically prioritizing, we limit these effects and optimize impact versus effort.
"We do not see sustainable design as a limitation, but as a design challenge. Every concept is measured against sustainability criteria, from the overall design down to the smallest details."
Space and circularity as sustainability factors
Sustainability goes beyond materials and energy; space utilization and circularity are equally crucial. By designing machines compactly, combining functions, or organizing them vertically, we reduce footprint and material consumption. A smart layout improves efficiency in operation, maintenance, and logistics, while aligning with circular principles.
In practice, this often means combining space savings and reuse:
- Automation projects: one complex mold replaces multiple simpler molds, saving floor space and increasing flexibility.
- Refurbishment projects: existing machines and installations are given a second life. By retaining or reusing components during maintenance or redesign, we reduce material usage and extend system lifespan, preventing unnecessary production of new parts and conserving raw materials.
- Infrastructure projects: recalculations of lock gates and drive systems show that existing components often have sufficient strength and remaining service life, eliminating the need for replacement.
"The challenge is finding the right balance between effort and result. You can optimize endlessly, but the key is knowing when additional engineering hours truly add value."
We also continuously assess maintenance and lifespan. By thinking practically during design and site visits, we often discover new ways to extend component usage and save energy and materials.
In infrastructure as well as offshore projects, this is reflected in repairs through welding overlays or machining bores instead of applying entirely new steel. In this way, our designs align directly with real-world conditions and the principles of reuse, repair, and refurbishment.
Sustainable design equals total lifecycle thinking
Sustainable design becomes even more relevant when considering the total lifecycle and total cost of ownership (TCO) of a machine:
- Less energy → lower operational costs
- Less mass/material → faster and more cost-effective production
- Less space → more efficient factory halls and offshore mission equipment
At MechDes, we integrate all these factors into the design process. Not through standard solutions, but through thorough engineering from concept to realization. Sustainability starts with philosophy and approach, not with materials alone. Every new challenge is an opportunity to use motion more intelligently: less energy, less mass, more efficient use of space, and optimal performance.
Space is becoming increasingly important. Floor area is scarce, not only in automation and intralogistics, but also offshore, where vessel dimensions often form the limiting factor. Designing compact, efficiently aligned machines will become essential in the coming years, even in markets where floor space used to be abundant. Where clients previously did not prioritize space reduction, it is now increasingly becoming a key requirement.
MechDes: designing for today and tomorrow
For more than 30 years, MechDes has been designing machines with attention to people, environment, and results. Our engineers combine technical expertise with a critical view on sustainability, efficiency, and circularity. The result is machines that perform while using energy, materials, and space as efficiently as possible.
By continuously balancing motion, energy, materials, and space, we realize designs that achieve more with less. This is not an abstract concept, but daily practice: from special machines in automation to complex infrastructure installations and offshore projects.
With Less is More, we strive for smarter, lighter, and more energy-efficient solutions. In doing so, machines remain not only functional and reliable, but also future-proof.
