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

Xbox One X

System integration + mechanical engineering


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

Affiniti 50/70

Engineering a lighter, smaller, more intuitive cart.

Cota Remote Wireless Charging

The next generation of Remote Wireless Charging.


An RFID gateway that's both beautiful and functional

Therapeutic Ultrasound

The next generation of HIFU systems

Xbox One S

Xbox One S system integration + mechanical engineering

Ping Pong

An exploration of process, form + finish

Philips Industrial Cable Flex Tester

a complex, impedance-based ultrasound cable tester

Premium Banking Kiosk

Concepts for an interactive retail kiosk

Xbox Kinect

Pensar's partnership with Microsoft continues with the Xbox Kinect

Xbox One

Microsoft partners with Pensar for mechanical integration and execution

DNA Shoe

What if your shoe was based on your anatomy + biomechanics

The Halo Light

See and be seen in low light conditions

Gamer Pro

Designing the flagship controller for a family of iOS gaming devices

Gamer Light

Changing the mobile gaming experience

Xbox 360

Engineered to be smaller, sleeker and as quiet as ever

Xbox Speed Wheel

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

Laser Distance Meter Family

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


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

Lifepak 15

Physio-Control's Lifepak line of mobile defibrillators


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

Gamer Arcade

Designing the next generation of arcade gaming for iOS

Optiks Lens Line

Performance-enhancing eyewear of the digital generation

Quinton 9500/9550

Complete redesign of Quinton's industry-leading stress cart

Burdick 8500

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

Xbox 360 Slim

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


Pensar was tasked with making the MTurbo bulletproof

350 Paddle

The lightest strongest paddles ever made


MicroMaxx is user-focused, high-performance ultrasound


Mobile Docking Station Enhanced


Cardiology focused mobile ultrasound


Unprecedented ergonomics in the ultrasound market

LED Lighting

Recessed LED lighting and display case

Therapeutic Ultrasound Generation 1

Mechanical engineering for HIFU stystems


Teaming up to ease the burden of water collection in Ethiopia

A long history of cart development

A collection of medical carts Pensar has helped develop

Cota Charger + Battery

Concepts for the next generation of Remote Wireless Charging.

CX50 Cart

Faster development time and reduced cost


A place to honor the projects we can't show

MorphoTrak Access

Smart card access control integration