Selected work

Engineering that shipped

Five projects drawn from our client work, spanning robot cells, machine vision, custom motor control and industrial IoT. Each one started as a defined scope and ended as hardware running in production. We keep client identities confidential, so we describe the engineering, not the names.

Identifying details are withheld under our confidentiality commitments. References are available on request.

01Logistics

Tote handling robot cell for a distribution warehouse

The challenge

A manual lift station moved loaded totes between two conveyor levels. It became the bottleneck of the whole line at peak hours, exposed staff to repetitive heavy lifting, and could not keep up with rising throughput targets.

What we engineered

We designed a 4-axis handling robot around the tote geometry, integrated it with the existing conveyors, and added a safety PLC with interlocked guarding. The cell was built and tested in our workshop, then installed and commissioned on site over a single weekend.

Outcomes

From concept to commissioning in 14 weeks
Zero unplanned stops in the first quarter of operation
Operators moved from lifting to supervising the cell

02Food production

Vision inspection station for a packaged food line

The challenge

Label and seal defects were slipping through manual spot checks and reaching retail shelves. Every escape risked a costly retailer complaint, and slowing the line for closer inspection was not an option.

What we engineered

We built an inline inspection station: an industrial camera, a controlled lighting rig and a pneumatic reject actuator. The software checks every pack for label and seal defects at full line speed, and a line-side HMI shows live results with per-product settings.

Outcomes

Every pack inspected at full line speed
No defect escapes reported since commissioning
Product changeover from the HMI in under a minute

03Machinery

Custom BLDC servo drive for a packaging machine OEM

The challenge

The OEM's machines depended on an imported servo drive that reached end of life. Redesigning around another vendor's drive meant new wiring, new firmware and months of requalification across the product range.

What we engineered

We engineered a drop-in replacement: a 4-layer motor drive board with carefully tuned FOC firmware, pin-compatible with the legacy harness and matched to the original control interface. It mounts in the existing machine with no electrical or mechanical changes.

Outcomes

Pin-compatible with the legacy harness, no rework
Smoother motion than the original drive after FOC tuning
Full design ownership: schematics, layout and firmware source

04Building services

Industrial IoT retrofit for chiller plants

The challenge

A facilities operator ran chiller plants across several sites with no remote visibility. Faults surfaced only after tenants complained, and manual meter rounds consumed technician hours every day.

What we engineered

We deployed a LoRa sensor network through the plant rooms: battery-powered nodes on chillers, pumps and headers, a gateway at each site, and a dashboard with configurable alerts. Clamp-on and strap-on sensors kept the installation non-invasive, so no plant was ever stopped.

Outcomes

Installed and live with zero plant downtime
Faults flagged by alerts before tenants notice
One dashboard replaced the daily meter rounds

05Consumer products

Consumer IoT device from prototype to production

The challenge

A founder arrived with a working MVP built on development boards and hand-soldered modules. It proved the idea, but it could not be certified, manufactured at scale or priced for retail.

What we engineered

We redesigned the electronics as a single custom PCB, engineered the enclosure for injection molding, and prepared the compliance path for CE marking. We then supported the pilot run at the contract manufacturer, from test fixtures to first articles.

Outcomes

One custom board replaced three development modules
Passed CE pre-compliance testing on the first attempt
Pilot run delivered with test fixtures and assembly documentation

Your project could be next

Describe the machine, product or plant you have in mind. We reply with a scoped, fixed-price quote, usually within two business days. Prefer to talk it through first? Book a session with an engineer.

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