Excessus Enterprises
Digital Design. Local Fabrication. Real-World Results.
Bridging the gap between creativity and precision manufacturing — from concept to production, we design, prototype, and fabricate unique parts and products with modern digital tools.
About Our Mission
At Excessus Enterprises, we help creators, makers, and small businesses turn ideas into tangible products.
We're a design-to-manufacture startup integrating 3D printing, laser cutting, and CNC milling into a streamlined creative service. Our mission is to make professional-grade design and fabrication accessible to individuals, startups, and small manufacturers who need custom, one-off, or low-volume production.
Work Portfolio
Real-world projects showcasing design, iteration, and functional prototyping
Hallway Motion Nightlight (v1)
Motion-Ready LED nightlight for low-light navigation
- • PIR sensor and ESP32-like microcontroller ready
- • Designed to extend non-blocking for extra components
- • USB based power fits economical outlet power adapters
- • LED strip has integrated diffuser and resistors
Watering Can with Combo Spout
Stable weighted base with embossed branding options
- • Multiple branding variants tested for visual appeal
- • Weighted design for improved stability
- • Threaded caps for interchangeability
- • Pour and shower in one cap
Fish Food Shaker (Threaded + Dispensing)
Precision-dispensing container with threaded lid
- • Controlled portion dispensing
- • Customized for specific food blends
- • Prevents accidental food "dumping"
- • Food-safe material considerations
Stairwell Motion Light
Motion sensor on opposing wall and custom light bar
- • Designed to integrate with existing environment
- • PIR motion sensor on the "headout" triggers for up/downstairs correctly
- • Arduino interprets PIR and triggers relays
- • Custom resin lightbar with 12V LED vehicle-style lamps
Hallway Motion Nightlight (v1)
This project is a solution for safe nighttime navigation without harsh overhead lighting. The first successful integration is direct 5V from USB to the LED strip. The design is ready to integrate a PIR motion sensor and microcontroller. Those components can let the LED be PWM limited to low output until motion is detected. Using the USB interface avoids exposing 120VAC and allows economical wall adapters of many varieties.
Key challenges included managing wire routing within a compact space, designing an effective light diffuser and LED length for soft ambient glow, and ensuring the enclosure could be assembled and serviced easily. Multiple iterations refined the retaining features and LED mount aperture. Wire management would be quite different with a microcontroller.
What I Learned / Iteration Notes
- • Curved face designs limit 3D FDM retaining features
- • Change the wiring cross pattern to black under red in this case
- • This silicon diffuser did not compress lock as well as expected
- • Hot glue can be handy but, like soldering, there is an art to it
Project Gallery
Finished assembly, front view
Internal components and wiring
Finished open
Lighting the hallway green
In use closeup
Distant low-light capture
Design Screenshots
Fusion 360 - Main enclosure design
Assembly view with all components
Watering Can Base (Branding / Labeling Variants)
An indoor watering solution vs metal outdoor cans or traditional plastic designs. The base is oval and wide for stability with a unique textured grip. Different caps / spouts can be interchanged based on the plant's watering needs.
This project explored how different embossing depths and geometries affect both aesthetics and print time. It also tests not just water tightness, but handling a PLA FDM printed object of weight while wet.
What I Learned / Iteration Notes
- • Weight distribution testing with filled can informed final base geometry
- • Embossing depth vs. print time (and failure) tradeoff — shallow reliefs print faster, but will less tactile effect when wet
- • Embossing or extruding letters on a curved face pushes software limits
- • Water division between spouts is good, but could be better with a higher and steeper dome apex
Project Gallery
Textured handhold and labeled
Branding ExE example
Lettering and texture zoom
Shower and pour spout in one
Assembled base and spout top
Fusion Design
Fish Food Shaker (Threaded + Dispensing)
A custom container for controlled fish food dispensing with a threaded, dump-resistant lid. The design includes precision holes for portion control and a thread profile optimized for 3D printing tolerances.
Thread design required multiple test prints to achieve smooth engagement without binding. Material selection considered food-safe filament options and moisture resistance for aquarium environments.
What I Learned / Iteration Notes
- • Thread pitch and clearance are critical — 0.2 - 0.4mm tolerance worked best for PLA
- • Embossing with curves vs sharp angles and printing text vertical
- • Dispensing hole size impacts portion consistency — multiple sizes tested
- • Ribs on the cap solved a visual consistency issue with the cap holes layer and provided support
Project Gallery
Assembled shaker, closed
Shaker holes and ribs
Threads are great, but there is a sane upper limit. ;)
Stairwell Motion Light
A multi-part motion and lighting solution for a complex location. The lightbar is red tinted epoxy/resin, specially mounted above the door frame, and contains two vehicle running lamp equivalent LEDs. The system is powered by 120V AC input 12V DC output PSU. The PIR is mounted on the wall to catch the door opening and people ascending only trip the sensor when halfway up, thus preventing accidental tripping by people walking below
After creating the lightbar, this project had been on hold for months and was a major tipping point to start printing my own parts. Felt great to be able to put the electronics in place and see them work.
What I Learned / Iteration Notes
- • Resin has some mild weight so some snap testing was performed for the PLA. :)
- • Lots of tiny wire splicing and soldering before making any usable connections
- • Don't put bracket mount holes too close to edges and corners
- • Center of mass isn't always where expected, but lead weights work in a pinch
Project Gallery
Resin and 12V LED lightbar
12V power supply and relays
Sensor and controller layout
PIR as mounted on defunct fire detector
Arduino powered for automation expansion
Fusion Design
Exploratory & Early Prototypes
Explorations, test prints, and early prototypes — included to show process and iteration
Magnetic sewing needle and pin holder
Smaller version fits on standard mag holder
V-groove-like parametric organizer drawer
Creases, strings, errant forms while learning
PETG and O-Ring test ready
Customizable in Python using CADQuery
Bushing / screw clamp for threaded rods
Trapezoidal rail guide and round base plate
Have an idea? I can prototype it.
From concept sketches to functional prototypes, I bring experience in iterative design, material selection, and manufacturing constraints.
ContactWhat We Do
Comprehensive digital fabrication services for makers and businesses
Custom & Commission Prints
Unique prints made to order, either directly or through our designer network.
Design Brokerage
Connecting clients with skilled CAD designers for product development.
Printable Design Support
Helping refine or repair models to be manufacturing-ready.
Rapid Prototyping
Small-batch production for prototypes, marketing samples, or limited runs.
Replacement Parts on Demand
Functional reproductions, repair components, or discontinued parts.
Future Capabilities
Laser engraving, precision milling, and integrated smart device components.
Coming Soon
We're currently building out our fabrication network and workflow automation.
Interested in collaboration, early access, or prototype work?
Reach out — we're open to partnerships and pilot projects.
Get In Touch
Whether you're looking for custom fabrication services or exploring collaboration opportunities, I'd love to hear from you.