In the rapidly evolving field of unmanned aerial vehicles, maximizing flight time is critical, but so is operational efficiency. Securing heavy drone batteries traditionally involves cumbersome straps or complex locking mechanisms that delay field replacement and risk pilot error, potentially leading to power failure during flight.

Our client — an emerging innovator in drone technology — partnered with us to engineer a robust, lightweight, and user-centric battery lock system. The primary objective was to design a mechanism capable of safely securing a high-capacity battery under the aerodynamic stresses of flight, while allowing ground crews to swap batteries in seconds.

Using Solidworks, our mechanical engineers refined the geometry, focusing on minimizing weight without compromising strength. Finite Element Analysis was conducted using ANSYS Workbench to simulate extreme load cases including high-G maneuvers and vibrational resonance during flight.

The final design features a positive locking mechanism that provides audible and tactile feedback to the operator, ensuring the battery is securely seated. The mechanism was designed for tool-less operation, utilizing high-strength, engineering-grade polymers for the housing and hardened steel for the locking pins to balance weight and durability.

In industrial warehousing, traditional static shelving often requires forklifts or manual lifting to access heavy materials, leading to inefficiencies, workplace injuries, and space utilization challenges.

Our client, a developer of advanced storage solutions, partnered with us to perform the structural design and validation of a new multi-bin storage bunker equipped with an electric hoist system. The objective was to create a robust, high-capacity storage solution that allows operators to safely raise and lower heavy bins as needed, eliminating the need for manual lifting or forklift maneuvering in tight spaces.

Working in close collaboration with the client's engineering team, our mechanical designers developed a modular bunker system capable of supporting significant static loads while accommodating the dynamic forces of the hoist mechanism. Finite element models were built and computed using ANSYS to validate structural performance under various load conditions.

The bunker system was designed with multiple independent bins, each capable of holding substantial loads. The hoist rail system and support structure were specifically analyzed to withstand the point loads and dynamic stresses of repeated lifting cycles, with deflections remaining within acceptable limits for smooth operation.

The goal of this project was to perform a comprehensive computational fluid dynamics analysis of a generator cooling system to evaluate and optimize thermal management performance. The generator was designed with an active cooling system; however, concerns regarding temperature distribution and airflow efficiency required detailed investigation to ensure long-term reliability and prevent potential overheating issues during continuous operation.

Our team developed a complete 3D CAD model of the generator assembly using Siemens NX, capturing all critical components including the housing, rotor, stator, cooling fins, and fan assembly. This detailed geometry was then prepared and imported for CFD simulation using ANSYS to analyze the complex fluid flow and heat transfer phenomena within the generator enclosure.

The CFD analysis employed a conjugate heat transfer approach, simultaneously solving for fluid flow and solid heat conduction through generator components. The simulation revealed critical insights into airflow patterns, identifying regions of recirculation and stagnant air around high-temperature windings and bearing assemblies.

Based on the simulation results, design recommendations were developed to optimize cooling performance, including modifications to internal baffle geometry, improved fan blade configuration, and strategic placement of ventilation openings.

Cold heading machines operate under extreme cyclic loads, subjecting critical components to repeated impact forces that can lead to fatigue failure, misalignment, and unplanned production downtime. Our client, a manufacturer of industrial forming equipment, engaged us to perform comprehensive mechanical design validation and motion analysis of a new cold heading machine.

Using Siemens NX, our mechanical engineers developed detailed 3D models of the complete machine assembly, including the main frame, crankshaft, connecting rods, ram assembly, and die holders. To visualize and validate the machine's complex motion, we created detailed Siemens NX animations demonstrating how rotational input from the motors is converted into precise reciprocating motion of the heading tools.

Finite Element Analysis was performed using ANSYS to evaluate stresses in the most demanding components. Static structural analyses were conducted on the main frame under maximum tonnage conditions to verify stiffness and alignment retention. Fatigue analysis was applied to the crankshaft and connecting rods, which experience millions of high-impact cycles, ensuring they would meet the required service life without crack initiation.

In the automotive and trailer manufacturing industry, reliable electrical connections are critical for safety and regulatory compliance. Technicians and inspectors require durable, portable test equipment to quickly verify wiring integrity and diagnose faults in trailer lighting systems.

Our client engaged us to design a robust trailer light wiring test box capable of withstanding the rigors of shop floor use while providing accurate and reliable electrical testing functionality. The objective was to create a compact, ergonomic enclosure that would house the necessary testing circuitry, connectors, and indicators while surviving repeated drops, tool impacts, and exposure to common automotive fluids.

Using Creo, our mechanical engineers developed detailed 3D models of the test box enclosure, internal component mounting features, and connector interfaces. To validate mechanical durability, Finite Element Analysis was performed using ANSYS — drop test simulations evaluated impact protection, structural analysis verified resistance to point loads, and vibration analysis ensured component reliability during transport in service vehicles.