Change an input, rebuild the package

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  The part

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  Strip progression

The die that stamps the stator laminations for the 3115 drone motor further down this page: a 12-tooth, Ø31 mm disc in 0.2 mm electrical steel, 75 of which stack into one 15 mm motor core. It blanks them from 33 mm coil strip across six stations at about 3.6 tonnes, and the strip layout, station order, punch geometry and tonnage all come off the lamination itself — so changing the motor re-sequences the die rather than sending it back to the drawing board.

Capability demonstratedProduct Development →

The fabricated steel stand a machine bolts down to — roughly 1.2 by 0.8 metres, 19 cut pieces of tube and plate, sized to carry a half-tonne point load. The study treats it as a fabrication problem rather than a modelling one: weld sizing, member slenderness, torch access and saw capability are all evaluated first, and the geometry is whatever those rules allow.

Capability demonstratedAnalysis & Optimization →

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  Wire path

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  Dropout slug

A D2 tool-steel piercing die insert — a 55 by 50 by 20 mm block, corner-bolted into a die-set pocket, with a six-lobe opening cut through it to pierce 1.5 mm sheet. The block is hardened to 60 HRC and ground flat before the wire ever touches it, so nothing after that point can be corrected by machining and the cut plan has to carry every allowance itself. The lobe form stands in for any closed profile — a gear, spline or collet silhouette runs the same machinery.

Capability demonstratedManufacturing Enablement →

Five delta-wing concepts, each split into an upper and a lower skin at the chord surface so every shell lifts straight off a rigid tool — re-entrant area is zero across all five, and nothing has to be walked out of a cured part. The open question was whether one reconfigurable bed could stand in for those machined tools: a shared plate, a 2 mm spring-steel skin and a field of screw posts, with only a leading-edge rail cut per concept. It holds the surface to 0.29 mm against a 0.30 mm budget, covers 90 to 93 per cent of the chord — and still loses to simply machining the tool.

Capability demonstratedProduct Development →

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  CAD vs render

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  1404 toothpick

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  3508 cine

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  6215 agri

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  12110 eVTOL

An outrunner for 6- to 9-inch heavy-lift and long-range drones: 31 mm stator across, a 15 mm stack of 12-tooth laminations, 14 magnets and a 0.36 mm airgap, run off 6S at up to 22,000 rpm and 25 A continuous. It is one of sixteen motors built from the same generator — from a 14 mm toothpick motor to a 121 mm eVTOL unit — and it is also where the stamping die upstream gets its lamination, so changing the stack moves both the motor and its die.

Capability demonstratedProduct Development →

Illustrative: a representative motor built to exercise the method, not a qualified flight part.

An electric fixed-wing model driven from a single specification file through aerodynamics, propulsion and structures into a manufacturing release set. The full chain rebuilds in dependency order and reproduces its committed reference results byte for byte.

Capability demonstratedAnalysis & Optimization →

A 3U CubeSat built out as an integrated system on the open CubeSat Design Specification — the public standard that fixes the 100 × 100 × 340.5 mm envelope, the 4 kg mass cap and the rail geometry a dispenser grips. The PC/104 stack governs the interior on the same terms: 90 × 96 mm boards on 15.24 mm centres. Frame, shear panels, endplates, deployable solar wings and payload carrier are solved against both interfaces at once — and where a vendor does not publish a dimension, that parameter stays flagged and blocks release rather than being guessed.

Capability demonstratedPrototype Development →

A from-to wirelist becomes the package a harness shop builds from: a full-size pin-up board with a printed scale check bar, the pegged tooling to hold it, and the test map to prove the finished assembly.

Capability demonstratedManufacturing Enablement →