What we can do together
If you have a machine or robot to design and build, need parts produced in batches with reliable quality, or just want to talk about a career path, an idea, or preparing for an award — I'd be glad to talk.
Design, build and production
Custom machinery, designed and built
Need a machine that isn't on the market, or whose foreign equivalent is expensive and out of reach? I design it from concept and calculations to manufacturing drawings, and follow fabrication, assembly and commissioning through to delivery.
Multi-robot mobile fleets and service robots
Design and build of mobile robot fleets for sorting and moving loads in warehouses and distribution centers, and of service robots — from chassis and drive system to load mechanisms and preparation for batch production. 280 postal sorting robots across three generations came out of this work.
Batch production of quality-controlled parts
If you need industrial parts in batches and want them delivered with an engineering-driven, professional process and quality control: drawing review and GD&T, choice of manufacturing method, management of machining and fabrication workshops, and dimensional and weld inspection. More than 8,000 industrial parts have been delivered this way so far.
Automation, PLC and commissioning
Automation architecture, PLC programming (Delta and Siemens), HMI design and motion control — for a new machine or to upgrade one you already have.
Laboratory and medical test rigs
Standards-based test rigs for labs, universities and medical device makers — such as the knee prosthesis tester built to ASTM F1223, and a friction test rig whose data led to a paper in Scientific Reports.
Prototyping and redesign for production
Turning a prototype into a product that can be made cheaper, faster and with consistent quality. In the third-generation postal sorting robot, weight dropped from about 30 to 10 kg, speed rose from 1.1 to 1.8 m/s, and the footprint shrank from 70×70 to 55×55 cm.
Consulting and conversations
Part of what I've learned over these years is useful to someone just starting out on the same path.
Engineering career consulting
For students and engineers who want to get from university to real design-and-build work: choosing a field, building a portfolio, and finding a way into industrial projects.
Preparing for festivals and awards
If you have a project you want to present at festivals such as Khwarizmi or for awards such as the Alborz Prize: how to present the problem, the innovation and the results clearly and convincingly. Backed by two 2nd places at the Khwarizmi Youth Award and an Alborz Prize selection.
A technical chat about your idea
Have an idea and don't know where to start, or just want to talk through a technical problem? Send a message.
How we work
First conversation
I listen carefully to the need, constraints, budget and timeline — by message, call or meeting.
Technical review & proposal
A written proposal with the solution, scope, schedule and cost.
Design
Mechanical design, calculations and manufacturing drawings, reviewed with you at each step.
Fabrication & quality control
Follow-up of part fabrication and assembly, with dimensional inspection and QC.
Delivery & commissioning
Installation, testing, commissioning and documentation.
Frequently asked questions
Who is Hassan Nasiri Khonsari?
Hassan Nasiri Khonsari is an Iranian mechanical and mechatronics design engineer with an MSc in Applied Design from Sharif University of Technology. He led the mechanical design of Iran National Post's postal sorting robots across three generations and built a knee prosthesis constraint and stability test apparatus. He is a laureate of the 64th Alborz Prize and a two-time 2nd-place winner of the Khwarizmi Youth Award.
What kind of projects do you take on?
Custom machinery design and build, mobile and service robots, laboratory and medical test rigs, automation and PLC, redesign for production, and quality-controlled batch production of industrial parts. I also offer career consulting and help with preparing award applications.
Do you only design, or also follow fabrication?
Both. Almost all of my projects went from design through fabrication, assembly and commissioning, and ended with a delivered, working machine.
How do you handle batch production with quality control?
I review drawings for manufacturability and tolerancing (GD&T), choose the manufacturing method, manage machining and fabrication workshops, and parts get dimensional and, where needed, weld inspection before delivery. More than 8,000 industrial parts have been delivered this way.
What does award consulting include?
Helping you present the problem, the innovation, the results and the impact of your project clearly and with evidence — from writing the summary to preparing for judging and in-person presentation.
Is consulting in person or online?
Both are possible. I'm based in Tehran, and conversations can also happen by phone, Telegram, Bale or an online meeting.
What are your key projects?
Postal sorting robots (80 robots in Tehran and Kermanshah, third generation produced as a 200-unit series), a knee prosthesis constraint and stability test apparatus per ASTM F1223, five industrial 3D printers, a dual-purpose industrial CNC and a fleet of waiter robots.
How do we start?
Use the form at the bottom of the page, Telegram, Bale or phone and briefly describe what you need. If you have drawings, photos or samples, send them up front so the first conversation is more precise.
Contact
For design-and-build projects, batch production of parts or consulting, use the form below or any of the other channels.
Other channels: