Founded by Doug Saunders, our company specializes in machine design and integration, assembly automation, test equipment integration, and manufacturing fixturing. With a strong focus on efficiency and innovation, we help bring reliable, production-ready systems to life.
Doug, a native of Plainfield, Illinois, established DCS Designs after recognizing early in his career how critical test equipment is to successful product development. Drawing on over 15 years of experience as a Director of Engineering and Product Development across multiple industries, he has led the rapid development of products ranging from plumbing valves to livestock feed equipment—always with a focus on smart integration and practical results.
Automated Solutions, Engineered Right
Welcome to DCS Designs, your choice for self-operating test and assembly solutions
Innovative automation solutions built for real-world performance.
solutions
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Complete 3D CAD design for manufacture and analysis of components and complete assemblies.
3-D Modeling
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Design test stands for testing/evaluation of product designs, IQC/OQC, life cycle evaluations.
Automated Test Equipment
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Design 3D solid models using state-of-the-art CAD system, including working drawing and documentation.
Complete Documentation
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Automate your assembly and packaging needs into an accurate, reliable, repeatable mechanical assemblies.
Automated Assembly & Packaging Systems
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Develop machining, welding, assembly, glue, and measurement fixturing for world class manufacturing..
Manufacturing Fixtures & Tooling
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Sheet Metal, Machined, Injection Molded, and Rapid Prototype and part design.
Part Design
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Solution
Glenn Johnson, CEO Hi-Tech Electronic Products & Mfg., Inc.
"We were in the process of developing a unique product and needed to design the product as well as an automated production line to handle the volume. DCS Designs was our solution. At all levels of design and assembly, no detail went unturned. DCS Designs was instrumental in the first pass SOP and Assembly process of our newly developed product line. The fixtures developed assured us of consistent quality and greatly simplified the assembly process resulting in quick up-time for training the employee. Will use DCS Designs in all our future projects!"
Jeff Siegrist, Sr. Electrical Engineer Rely, Inc.
DCS Designs played a crucial role in our product development program by engineering custom environmental test chambers tailored precisely to our needs. Their versatility, technical expertise, and collaborative spirit made them an outstanding partner throughout the process. What truly sets DCSD apart is the personal touch they bring to every project—responsive, thoughtful, and deeply invested in our success. We couldn’t be more pleased with the results."
Steve Morriss, Owner/President
Midwest Packaging Automation Inc.
DCS Designs, LLC has been an exceptional partner on our recent projects. Their team provided outstanding support through the installation of conveyor systems, seamless integration of custom-designed equipment, and the execution of customer-requested repairs and improvements. Their attention to detail, technical expertise, and collaborative approach consistently resulted in high-quality outcomes. We truly appreciate their commitment to excellence and look forward to continuing our partnership.
Daryl Timms,
Dart Container
DCS Designs, has consistently delivered high-quality solutions across every phase of our projects. From installing equipment and conveyors to integrating complex systems and designing custom solutions, their work has been exceptional. Their ability to perform rapid component revisions—often with overnight turnaround—has been especially valuable. With strong mechanical design capabilities and expert sensor hardware installation, DCS Designs brings both precision and responsiveness to every job. They’ve been a trusted and dependable partner.
What cLients are saying
DCS Designs brings ideas to life through precise, fully realized 3D modeling that allows clients to see, evaluate, and refine their concepts long before anything is built. Using complete 3D CAD design, the team creates detailed models of individual components as well as full assemblies, giving clients a clear, accurate picture of how every part will function and fit together. This approach reduces uncertainty, improves communication, and helps ensure that designs are aligned with real-world manufacturing requirements from the very beginning.
By integrating analysis into the design process, DCS Designs identifies potential issues early, optimizes performance, and streamlines production. Clients benefit from faster development cycles, fewer costly revisions, and greater confidence that their systems will perform as intended. Whether designing a single component or a complex automated system, this 3D modeling process lays the foundation for efficient, reliable manufacturing solutions.
3D Modeling
DCS Designs brings ideas to life through precise, fully realized 3D modeling that allows clients to see, evaluate, and refine their concepts long before anything is built. Using complete 3D CAD design, the team creates detailed models of individual components as well as full assemblies, giving clients a clear, accurate picture of how every part will function and fit together. This approach reduces uncertainty, improves communication, and helps ensure that designs are aligned with real-world manufacturing requirements from the very beginning.
DCS Designs develops automated test equipment that gives clients a clear, consistent way to validate product performance at every stage of development and production.
These solutions support critical processes such as Incoming Quality Control (IQC) and Outgoing Quality Control (OQC), helping manufacturers maintain high standards while reducing manual inspection time and human error. By automating data collection and analysis, DCS Designs enables faster decision-making and better traceability throughout the production cycle.
DCS Designs develops automated test equipment that gives clients a clear, consistent way to validate product performance at every stage of development and production. From early design evaluation to final quality checks, custom test stands are engineered to accurately measure functionality, durability, and reliability. Each system is tailored to the specific product, ensuring that testing is not only thorough, but also efficient and repeatable.
These solutions support critical processes such as Incoming Quality Control (IQC) and Outgoing Quality Control (OQC), helping manufacturers maintain high standards while reducing manual inspection time and human error. By automating data collection and analysis, DCS Designs enables faster decision-making and better traceability throughout the production cycle.
For long-term performance, life cycle testing systems are designed to simulate real-world conditions and extended use. This allows clients to identify wear patterns, potential failure points, and opportunities for improvement before products ever reach the field. The result is greater confidence in product quality, reduced risk, and a smoother path from development to full-scale production.
Automated Test Equipment
DCS Designs provides complete documentation that transforms design concepts into clear, actionable resources for manufacturing and production teams. Using state-of-the-art CAD systems, every project begins with detailed 3D solid models that accurately define each component and assembly. These models serve as the foundation for fully developed working drawings, ensuring that every dimension, tolerance, and specification is clearly communicated.
DCS Designs provides complete documentation that transforms design concepts into clear, actionable resources for manufacturing and production teams. Using state-of-the-art CAD systems, every project begins with detailed 3D solid models that accurately define each component and assembly. These models serve as the foundation for fully developed working drawings, ensuring that every dimension, tolerance, and specification is clearly communicated.
Beyond the models themselves, comprehensive documentation packages are created to support the entire build and integration process. This includes assembly drawings, bills of materials, and any necessary technical notes, giving clients and their teams everything needed to move confidently from design to production. Clear documentation reduces ambiguity, minimizes errors on the shop floor, and helps streamline communication between engineering, manufacturing, and quality teams.
By delivering thorough and organized documentation, DCS Designs helps ensure consistency, repeatability, and long-term support for every system. Whether for initial builds, future modifications, or troubleshooting, clients have a reliable reference that keeps projects running smoothly and efficiently over time.
Complete Documentation
DCS Designs delivers automated assembly and packaging systems that transform complex, manual processes into streamlined, reliable operations. Each system is engineered to handle the specific requirements of your product, ensuring accurate part placement, consistent assembly, and efficient packaging. By combining mechanical design with intelligent automation, these solutions improve throughput while maintaining a high level of precision and repeatability.
From standalone workstations to fully integrated production lines, DCS Designs creates systems that scale with your operation. Automation reduces labor variability, minimizes errors, and ensures that every unit meets the same quality standards. Whether assembling components or preparing finished products for shipment, each process is optimized for speed without sacrificing control or accuracy.
The result is a dependable, repeatable workflow that supports long-term production goals. With a focus on durability and ease of integration, DCS Designs helps clients increase efficiency, reduce waste, and maintain consistent output—creating a stronger, more competitive manufacturing operation.
DCS Designs delivers automated assembly and packaging systems that transform complex, manual processes into streamlined, reliable operations. Each system is engineered to handle the specific requirements of your product, ensuring accurate part placement, consistent assembly, and efficient packaging. By combining mechanical design with intelligent automation, these solutions improve throughput while maintaining a high level of precision and repeatability.
Automated Assembly & Packaging Systems
DCS Designs develops custom manufacturing fixtures and tooling that bring consistency, accuracy, and efficiency to every stage of production. From machining and welding to assembly, adhesive processes, and precision measurement, each fixture is purpose-built to securely locate parts, guide operations, and reduce variability. The result is a controlled, repeatable process that helps ensure every component meets exact specifications.
Each solution is designed with both performance and practicality in mind. Fixtures are engineered to improve operator ease of use, reduce setup time, and integrate seamlessly into existing workflows. By stabilizing critical processes and minimizing human error, DCS Designs helps clients achieve higher quality output while increasing overall productivity.
With a focus on durability and precision, these tooling solutions support world-class manufacturing standards. Whether for high-volume production or specialized applications, DCS Designs provides the foundation for reliable, efficient operations that can scale and adapt as production demands evolve.
DCS Designs develops custom manufacturing fixtures and tooling that bring consistency, accuracy, and efficiency to every stage of production. From machining and welding to assembly, adhesive processes, and precision measurement, each fixture is purpose-built to securely locate parts, guide operations, and reduce variability. The result is a controlled, repeatable process that helps ensure every component meets exact specifications.
Manufacturing Fixtures & Tooling
DCS Designs provides comprehensive part design services that turn concepts into manufacturable, high-performance components. Whether working with sheet metal, machined parts, or injection molded designs, each component is developed with careful attention to function, material selection, and production requirements. The goal is to create parts that not only meet design intent but also perform reliably in real-world applications.
Using advanced design tools and rapid prototyping methods, DCS Designs allows clients to quickly evaluate and refine their parts before committing to full production. This iterative approach helps identify potential improvements early, reducing costly changes later and accelerating time to market. Every design is optimized for manufacturability, ensuring efficient production without compromising quality.
From initial concept through final design, DCS Designs delivers practical, production-ready solutions tailored to each client’s needs. By combining engineering expertise with a deep understanding of manufacturing processes, the result is a streamlined path from idea to finished part—built for performance, consistency, and long-term success.
DCS Designs provides comprehensive part design services that turn concepts into manufacturable, high-performance components. Whether working with sheet metal, machined parts, or injection molded designs, each component is developed with careful attention to function, material selection, and production requirements. The goal is to create parts that not only meet design intent but also perform reliably in real-world applications.
Part Design
DCS Designs delivers a comprehensive approach to product development and automation, combining product design, project management, budgeting, and quality assurance testing into a unified process. This end-to-end capability allows clients to move from concept to production with confidence, knowing that each stage is engineered for efficiency, accuracy, and manufacturability. The focus is always on creating practical, cost-effective solutions that perform reliably in real-world applications.
Founder Doug, a Plainfield, Illinois native, began his manufacturing career in 1987 and brings over 15 years of experience implementing retail product solutions for the home repair industry. His background includes designing custom automated dispensing systems and test equipment, giving DCS Designs deep expertise in both mechanical design and automation. Established in June 2020, the company reflects decades of hands-on industry experience applied to modern engineering challenges.
Doug’s technical foundation includes Tool and Die Apprenticeship training, along with Associate of Applied Science (AAS) degrees in Electrical/Electronic Automated Systems Technology and Mechanical Production Technology/Machine Tool Metalworking. He also brings practical expertise in PLC programming, Arduino development, and advanced CAD platforms such as SolidWorks, Pro/E, and Unigraphics. This combination of education and experience allows DCS Designs to effectively bridge the gap between design intent and production-ready execution.
DCS Designs delivers a comprehensive approach to product development and automation, combining product design, project management, budgeting, and quality assurance testing into a unified process. This end-to-end capability allows clients to move from concept to production with confidence, knowing that each stage is engineered for efficiency, accuracy, and manufacturability. The focus is always on creating practical, cost-effective solutions that perform reliably in real-world applications.
