Mechanical / Mechatronics Engineer – Next-Generation Tabletop Paper Converting Machine

I’m looking for a mechanical or mechatronics engineer with experience in paper converting, packaging automation, print-finishing equipment, or robotics to help design the next generation of an automated tabletop matchbox sleeve production machine. Project Overview I have an existing tabletop prototype that successfully performs the four pre-scored folds required to create a matchbox sleeve. While the concept works, I’d like to rethink the overall design to create a more modular, scalable, and automated solution. The current machine has several limitations: * The feeding mechanism operates reliably with a single sheet but begins to jam or feed inconsistently when multiple sheets are loaded, preventing continuous production. * The gluing operation becomes the primary bottleneck, limiting overall production output. * The machine requires frequent manual handling of individual sleeves between operations, making it difficult to achieve a truly hands-off workflow. * The existing design lacks the modularity needed to easily adapt to future sleeve sizes or additional production stages. Rather than refining the current machine, I’m looking for a fresh mechanical interpretation that achieves the same end result through a more elegant, reliable, and automated approach. Project Goals The objective is to develop a compact tabletop paper converting system capable of: * Reliable continuous feeding of pre-scored paper blanks. * Accurate folding while maintaining registration. * Minimal operator intervention during production. * Modular construction that can accommodate future sleeve sizes and additional processing stations. * Significantly increasing overall production output compared to the current prototype. Initial Scope I’d like to begin with a single folding module that performs the primary sleeve fold. The concept is to fold the pre-scored blank into a sleeve shape that can then continue through the remaining forming and gluing operations. Once this concept is validated, it can be expanded into a complete automated production line. I’m looking for an engineer who can think creatively about: * Reliable feeding of pre-scored paper blanks. * Precision folding without damaging the paper. * Mechanical simplicity and reliability. * Designing a modular system that can be adapted to different sleeve sizes with minimal hardware changes. * Creating a solution that reduces or eliminates manual handling throughout the production process. Existing Platform My current prototype is controlled using FluidNC and coordinates servo-driven mechanisms, actuators, and glue timing through CNC-style motion control. The engineer does not need to duplicate the existing mechanism—instead, I’m looking for a completely new design approach while maintaining compatibility with the current control platform where practical. Deliverables * Complete 3D CAD model of the mechanism. * Motion animation demonstrating the folding sequence and overall machine operation. * Recommended motors, actuators, sensors, bearings, and mechanical hardware. * Programming recommendations and control logic compatible with FluidNC. * Manufacturing-ready files suitable for 3D printing and prototype fabrication. * Assembly documentation and recommendations for future expansion. Ideal Experience Experience with any of the following is highly preferred: * Paper converting machinery * Packaging automation * Carton folding equipment * Print-finishing equipment * Robotics and pick-and-place systems * Servo motion control and machine automation The ideal engineer enjoys solving challenging mechanical problems and can propose innovative concepts rather than simply improving an existing design. My long-term vision is to develop a compact tabletop machine capable of continuously feeding, folding, gluing, and forming matchbox sleeves with minimal operator intervention and significantly greater overall production output than the current prototype. While I already have a functioning proof of concept, this project is about developing the next-generation version with a fresh mechanical approach focused on automation, modularity, and reliability.