CONVERGENCE
DESIGN SERVICES
AS AN EXTENSION OF YOUR TEAM,
We deal with the details.
Convergence is the trusted partner to de-risk your program, delivering proven expertise through seamless collaboration and a safe, scalable starting point. With a vast portfolio of experience, our multidisciplinary engineering team integrates seamlessly at any stage of development — from early concept through validation, compliance testing, and production.
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We provide mechanical, electrical, systems, and embedded design support, working within your tools, processes, and quality standards to maximize engineering output and reduce project risk. Our team routinely designs to demanding standards such as MIL-STD, DO-160, DO-254, and space-grade specifications.
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With a CGP-certified facility, advanced lab infrastructure, modern CAD tools, and cutting-edge hardware/software platforms, we support agile product development and co-engineered solutions from concept to completion — or anywhere in between.
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Specializations include:
Defence · Aviation · Mobility · Space
WE PLUG-IN AT ANY STAGE
Multi-Disciplinary Experts
With an experinced team of diverse talent, we are uniquely adaptive and well-positioned to solve your challenges and elevate the success of your product.
Prototype to Production
Prototyping is a crucial part of our design process that allows us to validate, verify, and refine your design before taking the leap to production. We take the steps required via various review gates to ensure that your product is built in the most effective, efficient, and scalable way possible to make the transition to production seamless and mitigate risk.
Verification & Validation
Working closely with our clients, we will detail our estimated cost to design, develop, qualify and transfer your concept into production.
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We offer complete life-cycle management for production support and obsolescence.
We keep it all aligned
Our agile project managers have a keen focus on cost, schedule, and scope management, ensuring that your project is completed on time, within budget, and to your specifications while proactively identifying and mitigating risks, managing procurement processes, and effectively communicating with stakeholders, resulting in successful project delivery.
HARDWARE DESIGN
PCB Layout | Schematics | Qualification & Testing
Convergence provides end-to-end hardware engineering for safety-critical aviation, advanced mobility, and defence systems.
From system architecture and component selection through schematic capture, PCB layout, and board bring-up, our team designs robust, high-reliability electronics optimized for performance, manufacturability, and long-term support.
We apply best-practice design rules, conduct comprehensive compliance and design assurance reviews, and support customers through qualification and certification for regulated environments.
Capabilities include:
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Architecture and Requirements Management (System, Hardware, Mechanical, Software)
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High-Speed Digital Design, HDD/ICD, PSpice, Signal, Layout Design, and Power Integrity Simulations
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Printed circuit board design, assembly, fabrication, and environmental testing
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Innovative hardware development and sensor integration for embedded and autonomous systems
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Automation, robotics, and electromechanical control hardware
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Secure, reliable wireless communications (Wi-Fi, cellular, Bluetooth, GNSS/GPS)
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Full certification and compliance support (UL, CSA, CE, IEC)
MECHANICAL DESIGN
Enclosures | System Architecture | 3D Modelling & Analysis
Convergence transforms early concepts into manufacturable, production-ready designs using advanced 3D modeling, structural, thermal, and vibration analysis to ensure performance, reliability, and environmental compliance.
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Our enclosure and system designs are developed to meet demanding environmental and ingress protection requirements, including IP-rated sealing solutions (IP65, IP67, IP68, IP69K) for dust, water, and fluid exposure. We design with RTCA DO-160 and applicable MIL-STD requirements in mind, addressing shock, vibration, temperature extremes, humidity, EMI/EMC, corrosion resistance, and long-term durability.
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We bring deep expertise in aerospace- and defence-grade materials, gasketing, sealing strategies, and precision tolerancing to ensure robust protection without compromising thermal management or serviceability. Our team delivers complete mechanical design package including enclosures, system architectures, and detailed drawings, supported by functional prototypes, environmental testing, and verification documentation to ensure every design is validated, sealed, and ready for qualification and production.
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Capabilities include:
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Mechanical and Product Design and Optimization: Material and manufacturing process selection tuned to volumes and production needs
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Thermal/Mechanical/Fluid Simulation & Engineering Analysis: Linear, non-linear, and dynamic
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Environmental Effects Testing: Derisking
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Design Verification Test and Failure Investigation
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Qualification Test Planning, Support and Formal Documentation
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New Product Introduction and Manufacturing Support
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Project Management
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Systems Engineering: Mechanical and electrical integration
MECHATRONICS
Electromechanical Systems | Controls | Embedded Integration
Convergence delivers integrated mechatronics engineering for safety-critical aviation, advanced mobility, and defence applications. We combine mechanical design, electronics, embedded software, sensors, actuators, and control systems to create reliable, high-performance electromechanical solutions operating in demanding environments.
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Our multidisciplinary team designs mechatronic systems with environmental, reliability, and qualification requirements in mind, supporting alignment with RTCA DO-160 and applicable MIL-STD standards for shock, vibration, temperature extremes, EMI/EMC, and operational durability. From motion control and actuation to sensing and closed-loop control, we ensure seamless integration across mechanical, electrical, and software domains.​
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Capabilities include:
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Architecture and Requirements Management (System, Hardware, Mechanical, Software)
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High-Speed Digital Design, HDD/ICD, PSpice, Signal, Layout Design, and Power Integrity Simulations
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Printed circuit board design, assembly, fabrication, and environmental testing
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Innovative hardware development and sensor integration for embedded and autonomous systems
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Dynamic Power Supply Design: Advanced ASIC/Micros (sequence, tight tolerance
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EMI/EMC: Design Techniques, Shielding, Common Mode Filtering, Ferrite
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Secure, reliable wireless communications (Wi-Fi, cellular, Bluetooth, GNSS/GPS)
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Space Supportive Analysis: Radiation hardness, outgassing, reliability, etc.
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Lightning Injection Simulation And Suppression: Transient Blocking Unit and Transient Voltage Suppression
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Circuit Simulation: Signal and Power Integrity Simulations
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Full certification and compliance support (UL, CSA, CE, IEC)
PROJECT MANAGEMENT
On Time | on Budget | On Point
Convergence provides dedicated project and program management for safety-critical aviation, advanced mobility, and defence programs. Your project manager serves as a single point of accountability, delivering continuous status reporting, risk visibility, and milestone tracking, so your program stays on schedule while you remain focused on core business priorities.
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Working in close collaboration with your team, we develop detailed cost, schedule, and resource plans covering design, development, qualification, and transition to production. Our approach is tailored to your manufacturing strategy, budget, and timeline, with full life-cycle management that includes production support, configuration control, and obsolescence management.
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We ensure programs meet or exceed technical, regulatory, and business requirements through structured design reviews, verification planning, and disciplined change management. Multiple review and verification cycles are executed throughout the program to reduce risk and deliver robust, qualification-ready designs.
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Capabilities include:
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Detailed program planning, scheduling, and budget control
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Clearly defined roles, responsibilities, and governance structures
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New Product Introduction (NPI) and production-readiness leadership
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Certification and compliance coordination (UL, CSA, CE, IEC)
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Consumer, industrial, and regulated product safety certification support
EMI / EMC CHAMBER
DO-160 | MIL-STD-461 | Pre-Qualification Testing
Convergence offers in-house EMI/EMC testing and engineering support for safety-critical aviation, advanced mobility, and defence systems. Through the acquisition of EMC Consulting from industry expert David Weston, we now operate a fully equipped EMI/EMC chamber and supporting procedures covering 9 kHz to 26.5 GHz.
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This capability enables comprehensive pre-qualification testing, compliance assessment, and EMI/EMC engineering debugging aligned to RTCA DO-160 and MIL-STD-461, including conducted and radiated emissions and susceptibility. Early identification and mitigation of EMC issues reduces technical risk, shortens certification timelines, and minimizes costly late-stage redesigns.
David Weston continues to support Convergence as a consultant and is actively training our engineering team, ensuring deep institutional expertise across EMC design, test execution, and failure resolution.
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By performing EMI/EMC engineering and debugging in-house, our customers avoid the high daily costs and schedule constraints of formal test laboratories. Access to our chamber, equipment, and EMC expertise is integrated into our engineering services—delivering faster iteration, lower program cost, and qualification-ready designs.​
ANECHOIC CHAMBER
Daily | Weekly | Monthly Rentals
Our facility houses a full-sized anechoic chamber that is an exact replica of the one at the NRC in Ottawa. This allows us to perform full-spectrum audio testing in a "zero" noise environment. We also have an in-house digital/audio lab, complete with the latest test equipment.
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18ft (5.5M) Full-sized anechoic chamber with B+K microphone, linear pre-amp, and signal conditioner
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Speaker frequency measurement response, distortion and impulse analysis in the chamber
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Large electronics lab with Audio Precision audio and distortion analyzer, true analog oscilloscope, etc.
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13 x 22ft (NRC) Listening room with sound dampeners, level matching, and instantaneous switching
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Acoustic transducer design/simulation (proprietary - voice coil design, cone, surround, spider)
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​​Magnetic field optimization using FEMM (Finite Element Method Magnetics)
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Customized enclosure modeling simulation utilizing a combination of LEAP, LspCAD, AKABAK, etc.
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Crossover network design/simulation
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3D carbon fiber driver basket printing + rapid driver prototyping available
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Driver Thiele/Small parameters and impedance measurement
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Cabinet resonance control accelerometer
