GreenLight Engineering Solutions is an independent consultancy providing specialist automotive and mechanical engineering services to OEMs, startups, and organisations that need expert technical support — from initial concept through to production-ready delivery.
GreenLight Engineering Solutions works across the full product development lifecycle. Whether you need a complete, independently delivered work package or specialist support embedded within your existing engineering function, we have the expertise to help.
Full vehicle platform concept development from initial layout definition through to architecture validation. We cover occupant packaging, major component positioning, platform feasibility, and cross-functional integration across passenger car, SUV, commercial vehicle, and specialist vehicle programmes.
Engineering support for the integration of complex systems across a vehicle or product — ensuring that powertrain, chassis, electrical, thermal, and structural elements work together effectively within defined packaging constraints. We help resolve multi-discipline conflicts and define clear interface requirements between systems and suppliers.
Concept and detailed design of front and rear suspension systems, steering geometry, and tyre envelopes — from initial layout through to production drawings. We work collaboratively with specialist analysis partners where dynamics and durability simulation is required, ensuring design intent is correctly captured and communicated.
Detailed 3D CAD modelling, 2D drawings, design specifications, homologation packages, and compliance documentation — produced to OEM standards using Catia V5, Siemens NX, or Onshape. This service also includes mass and centre of gravity tracking, axle load analysis, and the development of bespoke reporting tools to support programme-level engineering management.
Engineering support from initial concept through to productionisation — helping clients develop ideas into manufacturable, validated designs. We assist with concept generation, design for manufacture, supplier engagement, and prototype validation. With in-house FDM 3D printing capability, we can quickly produce physical parts for visualisation, fit checks, and proof-of-concept testing early in the development process.
Accurate recreation of components and assemblies from physical parts, legacy drawings, or scan data — producing clean, parametric CAD models and engineering drawings suitable for manufacture, modification, or supplier sourcing. Useful for obsolete parts, competitor benchmarking, design validation, and integration studies where original data is unavailable.
The following examples draw upon nearly two decades of engineering expertise gained across multiple disciplines and sectors. They reflect the depth of knowledge and practical capability we bring to every client engagement.
Concept and detailed engineering was led for a family of electric commercial vehicle platforms — from 7.5t to 12t — using a common platform architecture to maximise component sharing and reduce programme cost. Key responsibilities included defining architectural requirements, ensuring legislative compliance, collaborating with the design studio on surface feasibility, and delivering a lightweight prototype cargo box using innovative composite materials and construction methods.
Complete management of the front-end package zone for a purpose-built extended-range electric vehicle from concept through to production. The scope included cross-functional integration across chassis, powertrain, body structures and trim teams; preparation of homologation drawings for ECWVTA certification; prototype build support; and the development of a vehicle-wide mass and Centre of Gravity tracking process with bespoke BoM extraction tooling.
Comprehensive platform-level layouts were developed for a new range of electric sports and GT vehicles at an established UK performance OEM. The work covered occupant packaging relative to HV battery installation, drivetrain concept layouts enabling low cab-forward aesthetics, platform bandwidth investigations across market segments, and platform sharing studies to assess OEM collaboration potential. Internal HV battery concepts were also developed for current and next-generation cell technologies.
Engineering contributions were made to the design of high-voltage electrical and mechanical components for an advanced hybrid powertrain developed for motorsport application. The scope included bespoke HV connector design, battery cell carrier structures, and inlet port geometry modelling using advanced surfacing methods. Improved port area analysis workflows were also developed, alongside R&D instrumentation work including specialist spark plug and cylinder head design — all delivered to demanding programme timelines.
Regardless of size or complexity, GreenLight Engineering Solutions adapts to what your programme needs — whether that is a fully managed work package or specialist resource embedded within your team.
GreenLight Engineering Solutions is an independent consultancy founded to deliver senior-level engineering expertise directly to clients — with the responsiveness and accountability that larger organisations often cannot provide.
Our expertise spans nearly two decades across a wide range of engineering disciplines, including whole vehicle packaging, platform architecture, battery electric vehicle development, systems integration, and chassis engineering. This breadth of experience has been built across some of the most technically demanding programmes in the automotive industry.
We work with clients on-site or remotely across the UK and internationally. For larger commissions, we are able to draw on a network of trusted specialist collaborators to provide additional resource where required.
Every project benefits from genuine, hands-on senior engineering input — not account management or junior resource.
From established global OEMs to emerging technology companies and organisation that requires rigorous, senior-level mechanical engineering capability.
Whether you have a fully defined scope of work or are still shaping the brief, we welcome an initial conversation about how GreenLight Engineering Solutions can support your programme.