Project: Surface

Mechanical Engineering

Pensar helped Microsoft’s New Product Innovation group bring Surface to life. We are proud of our contributions, including the easy alignment and solid feel of the touch cover and it’s connection to Surface. We created self-aligning geometry and custom flex circuitry on the touch cover and Surface. We also optimized the magnetic forces that hold the two together.  Our prowess in tolerance analysis turned Surface into a high precision machine with just the right feel. Sam Biddle of Gizmodo says the touch cover is “a phenomenal engineering effort, and the most terrifically-integrated mobile keyboard ever.”

We had a lot to do with the fact that you don’t have to worry when you drop your Surface. Frankly, we like to drop stuff. This makes us masters at evaluating results from drop testing and optimizing features and framework to survive drops through structural and kinematic analysis. We used ANSYS LS-DYNA to do drop simulations before actual units were even produced. This provided direction on high level architecture, material selection and detailed design features. “First and foremost, I still firmly believe that Microsoft has built the best tablet on the planet in terms of hardware. Seriously.” – Zach Epstein, BGR media

The satisfying click when the kickstand flips out is music to our ears.  Through engineering optimization of a new custom hinge design we were able to deliver a kickstand that withstands a kick, but opens like the door on a luxury vehicle. “This is one of the most exciting pieces of hardware I’ve ever used. It is extremely well-designed; meticulous even.” – Mat Honan, Wired

We helped ensure Surface looks as slick in production as the designers dreamed by adhering to their strict dimensional requirements.  Our ability to Design for Manufacture and Assembly along with control documentation, means that the specifications we develop for each and every detail are maintained through production. This included developing a custom micro HDMI connector, USB connector, power button, volume button and camera mounts. The tight and angled spaces that create engineering challenges, also create wonderful user interaction moments. We excel at engineering in difficult spaces and we understand the importance of maintaining design intent. “The iPad feels pedestrian compared to the Surface.” – Matt Burns, Tech Crunch

Combining the disciplines of Industrial Design, Mechanical, Electrical, and Software Engineering, Pensar develops robust products that exceed expectations and are ready for the real world.  Contact us to discuss how we can help on your next project.

Project Gallery

Binocular Concepts

A binocular project that showcases our diverse design thinking

Xbox Series S

Small, Powerful, Affordable

Xbox Series X

High performance in a small package

R700 RAIN RFID Reader

Impinj R700 RAIN RFID reader for Enterprise IoT solutions

DLTA 360° Drone + App

Love for 360° images inspires a concept

Brush Heads

Innovative brush heads using new materials

SII Portable Ultrasound System

Portable Ultrasound for the Modern World

Undisclosed Projects + Clients

Better XR user experiences created daily


An RFID gateway that's both beautiful and functional


A place to honor the projects we can't show

CX50 Cart

Faster development time and reduced cost

Cota Charger + Battery

Concepts for the next generation of Remote Wireless Charging.

Therapeutic Ultrasound

The next generation of HIFU systems

Affiniti 50/70

Engineering a lighter, smaller, more intuitive cart.

Xbox One X

System integration + mechanical engineering

Xbox One S

Xbox One S system integration + mechanical engineering

Cota Remote Wireless Charging

The next generation of Remote Wireless Charging.


The new Illumagear Halo. It's cord-free!

Ping Pong

An exploration of process, form + finish

Therapeutic Ultrasound Generation 1

Mechanical engineering for HIFU stystems

Philips Industrial Cable Flex Tester

a complex, impedance-based ultrasound cable tester

A long history of cart development

A collection of medical carts Pensar has helped develop

MorphoTrak Access

Smart card access control integration

LED Lighting

Recessed LED lighting and display case


Cardiology focused mobile ultrasound

Xbox Kinect

Pensar's partnership with Microsoft continues with the Xbox Kinect

The Halo Light

See and be seen in low light conditions

Xbox 360

Engineered to be smaller, sleeker and as quiet as ever

Laser Distance Meter Family

We designed a family of laser distance meters that strengthens the Fluke brand

Xbox Speed Wheel

Race to your heart's content with this wireless, motion-sensing controller

Optiks Lens Line

Performance-enhancing eyewear of the digital generation

Xbox One

Microsoft partners with Pensar for mechanical integration and execution


Pensar helped Microsoft's New Product Innovation group bring Surface to life

Premium Banking Kiosk

Concepts for an interactive retail kiosk


Pensar was tasked with making the MTurbo bulletproof


MicroMaxx is user-focused, high-performance ultrasound

Xbox 360 Slim

Developing the best gaming console in existence is what we do every day

Lifepak 15

Physio-Control's Lifepak line of mobile defibrillators

Quinton 9500/9550

Complete redesign of Quinton's industry-leading stress cart

Gamer Light

Changing the mobile gaming experience

Gamer Arcade

Designing the next generation of arcade gaming for iOS

DNA Shoe

What if your shoe was based on your anatomy + biomechanics

Burdick 8500

Pensar updated the Atria ECG to embrace Cardiac Science's new design language

350 Paddle

The lightest strongest paddles ever made


Unprecedented ergonomics in the ultrasound market

Gamer Pro

Designing the flagship controller for a family of iOS gaming devices


Teaming up to ease the burden of water collection in Ethiopia


Mobile Docking Station Enhanced


Mobile ultrasound system that adapts to a variety of medical procedures and users