Business Details
25 Years
experience
Engineering & Product Design Services | Sherpa Design
Sherpa Design is a multidisciplinary engineering and product design firm established in 2001, dedicated to helping clients transform innovative ideas into market-ready solutions. Our team of experienced engineers, designers, and machinists specializes in end-to-end product development, from early-stage concepts to full-scale production and sustaining support. We leverage cutting-edge technologies like Carbon 3D printing, precision CNC machining, and Siemens Teamcenter PLM integration to deliver tailored engineering solutions across aerospace, automotive, consumer products, and defense industries.With ITAR certification and a focus on design for manufacturability, we provide collaborative expertise that bridges the gap between R&D and real-world implementation. Our proprietary NX CAD/CAM training programs and status as the first Carbon Global Design Partner underscore our commitment to advancing engineering excellence through continuous innovation and technical mastery.
Services
Product Design
3D Printing
CNC Machining
Teamcenter Consulting
NX CAD Training
Opto-Mechanical Design
Precision Machining
Additive Manufacturing
Engineering Consultation
Prototyping
Details
- Year established: 2001
Highlights and features
- We offer 20+ years of experience in product engineering and design since 2001
- Our team includes Siemens-certified Teamcenter experts and NX CAD specialists
- We maintain ITAR certification for defense industry compliance
- We pioneered the first Carbon Global Design Partnership for 3D printing innovation
- Our in-house machine shop enables rapid prototyping and precision manufacturing
Associations and certifications
- Carbon 3D Printing Global Design Partner
Services
3D Printing
Our Carbon 3D printing services enable rapid prototyping and end-use part production using digital light synthesis technology. We optimize designs for additive manufacturing, reduce support material requirements, and leverage industrial-grade materials with mechanical properties comparable to injection-molded plastics. Our three Carbon M2 printers and M3 Max system support bridge production runs of 10-10,000 parts annually while maintaining strict quality controls.
CNC Machining
Our on-site precision machine shop handles complex, high-tolerance components using DMG Mori DMU 50 five-axis CNC machining centers. Capable of 0.001" tolerances in metals and 0.006" in plastics, we specialize in small, intricate parts requiring tight tolerances and rapid turnaround. Services include first article inspection, reverse engineering, and CMM verification using Nikon measurement systems.
Teamcenter Consulting
We provide Siemens Teamcenter PLM implementation, configuration, and optimization services to streamline product lifecycle management. Our certified experts offer strategic consulting, workflow development, CAD integrations, and site assessments to align PLM systems with business objectives. With 40+ years combined experience, we support greenfield implementations and legacy system upgrades for aerospace and automotive clients.
Product Design
Our industrial design and mechanical engineering teams deliver complete product development from concept to production. Services include CAD modeling, FEA analysis, thermal studies, and design for manufacturability. We specialize in opto-mechanical systems, embedded electronics integration, and complex surface modeling using Siemens NX, SolidWorks, and Creo platforms for consumer, industrial, and defense applications.
NX CAD Training
We offer Siemens NX CAD/CAM training programs developed by engineers with 25+ years of practical experience. Courses cover foundation skills through advanced surfacing, additive manufacturing, and CAM programming. Available as onsite instruction or remote learning, our curriculum includes customized training paths for corporate teams and certification preparation for NX specialists.
People
Patrick Barrett
Owner
As founder and owner, Patrick leads Sherpa's strategic direction while maintaining hands-on involvement in complex engineering projects. With deep expertise in product development and manufacturing processes, he ensures the company's continued focus on technical excellence and client collaboration.
Randy Ellsworth
Director of Digital Transformation
Randy oversees Sherpa's digital transformation initiatives, specializing in Teamcenter PLM implementations. As a Siemens Solution Partner Legend, he brings 20+ years of experience optimizing engineering workflows and data management systems for aerospace and defense clients across complex regulatory environments.
Matt Martin
Senior NX CAD Admin
Matt serves as both Teamcenter architect and NX CAD specialist, supporting semiconductor, medical, and aerospace clients. A Siemens Community Catalyst awardee, he develops customized PLM solutions while maintaining active NX administration and training responsibilities for corporate engineering teams.
Bryce Copple
Teamcenter Application Engineer
Bryce provides Teamcenter expertise and electronic design tool integration, having graduated from Siemens' intensive Teamcenter bootcamp. He specializes in configuring PLM systems for complex engineering data management while supporting clients through software upgrades and process optimization.
Cameron Castillo
Electrical Engineer
Cameron focuses on electromechanical product design and firmware development. His work spans consumer electronics and defense applications, with particular expertise in sensor interfaces, embedded systems, and ruggedized enclosure design for harsh operating environments.
Questions
What industries does Sherpa Design serve?
We work with aerospace, automotive, consumer products, defense, industrial equipment, and semiconductor clients, adapting solutions across sectors through our multidisciplinary engineering approach.
Are you ITAR compliant?
Yes, Sherpa maintains ITAR certification for defense-related manufacturing and engineering services, with secure file handling processes for controlled technical data.
What 3D printing capabilities do you offer?
As Carbon's first Global Design Partner, we operate three M2 printers and an M3 Max system, supporting prototyping and bridge production using industrial-grade DLS materials.
Can you help with Teamcenter PLM implementation?
Our certified experts provide Teamcenter installation, configuration, workflow development, and integration services, along with customized training programs for engineering teams.
Do you handle small-batch production?
Yes, our precision machine shop supports low-volume, high-complexity CNC machining with tolerances down to ±0.001", specializing in parts requiring tight specifications and rapid turnaround.
What NX CAD training options exist?
We offer foundation through advanced NX CAD/CAM courses, including customized corporate training programs and specialized modules for additive manufacturing and reverse engineering applications.
