Hardware Development Services
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Copy of Manufacturing Projects

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Manufacturing Projects

The V1 Engineering team has brought a variety of projects from concept to prototype through to commercial readiness, specializing in a hands-on practical approach. Projects range from research and design, to early prototyping iterations, to fabrication of pilot equipment, to design for manufacturing and commercially ready production.

The V1 team has particular expertise in the industrial, manufacturing, and energy sectors. These highlighted projects have also provided familiarity with regulatory issues, and experience with a range of fundraising types, from angel level support to VC investment to strategic relationships. Clients range from startups to large industry players.


Roll Straightener

Client: Alcoa

Phase: Pilot Test in Plant

Design of a 3-roll extrusion straightening machine to automatically remove any residual curvature from annealed aluminum extrusions.

Key Skills:
modeling
control system design


Shuttle Panel Press Control

 

Client: Lockheed Martin

Phase: Pilot Test in plant

Design and fabrication of a 75-ton press control system to measure the curvature of milled aluminum panels for the Space Shuttle main external tank. The complex milled panels varied in stiffness in all axes, and were formed by incremental hits in the press. Our control system measured the small curvature of the panel after each hit using an innovative vision system design, and calculated the depth of the next hit required to keep the curvature within specifications.

Key Skills:
modeling
sensor systems
prototype fabrication


Configurable Die Press

Client: GM Corp

Phase: Pilot

Design and fabrication of a prototype automated configurable die press. The configurable die consisted of a set of die matrices formed by rows and columns of 1/4” rods which could be quickly set to any shape, then locked into the shape for forming sheet metal.

Key Skills:
fabrication
hydraulics
control system design


Packaging for Empire Parallel Processing Engine

Client: IBM

Phase: Proof of concept

Design of electronics hardware packaging to house, power, and cool 100 CPUs and associated memory, storage, and power systems. This prototype computer system for general purpose, massively paral- lel processing was designed to be scaled to 1000 processors.

Key Skills:
modeling
advanced control systems
thermodynamics
sheet metal fabrication


Automotive

Client: Various

Phase: Various

Team members have been involved in many elements of automotive design, fabrication, repair, restoration, etc. Vehicles include on- and off-road vehicles, motorcycles, custom vehicles, and industrial and construction vehicles.

Key Skills:
design
fabrication
engine build
suspension
bodywork
control systems


Plastics Mixing Container

Client: Saunders Foundry Supply

Phase: Commercial Product

Fabrication of large stainless steel mixing pots for batch processing of molten plastics. Design of the mixing pots required special fabrication techniques to guarantee purity of various batch recipes.

Key Skills:
fabrication
toolmaker


Microfluidics Manufacturing

Client: Singapore Institute

Phase: Pilot

Design and fabrication of a very low cost benchtop manufacturing system for microfluidic chips. The system is designed to be used for small-run microfluidic manufacturing, or design and development efforts.

Key Skills:

metal and non-metal fabrication
manufacturing
control systems
automation


Brushless DC Motor design

Client: Rotron

Phase: Commercial Product

Design of patented improvements to brushless DC motor design to be used in motor-fan combinations.

Key Skills:
patent
electronics
design


High-Reliability Motor/Fan

Client: IBM

Phase: Commercial product

Design of a specific motor/fan element to replace units that were failing prematurely in the field.

Key Skills:
patent
electronics
design
electronics fabrication


Factory Automation

Client: Rotron

Phase: Commericial Implementation

Redesign of factory flow process for manufacturing of consumer commodity motors and fans. Oversee construction of the factory through startup.

Key Skills:
project management
design
construction


Recording Studio Design

Client: Mosaic Ministries

Phase: Full Commercial Operation

Design and construction of an audio recording studio in an existing building. Key elements included acoustic isolation, power, cooling, wiring, and assembly and installation of all recording equip- ment. Also design and fabrication of a portable sound system for live sound applications and remote multi- track recording

Key Skills:
acoustics
automation
fabrication
woodworking


Restaurant Acoustics

Client: Cracker Barrel

Phase: Full Commercial Implementation

Measurement of sound levels throughout the restaurant and store to study noise problems for a normal operating day. Analysis of the noise patterns, and objectionable noise frequencies, and suggest modifications to the restaurant area to reduce cross-noise levels to improve customer experience.

Key Skills:
acoustics
modeling
construction


Microcontact Printing

Client: NSF

Phase: Pilot

Design, fabrication, and demonstration of hardware and control systems for contact printing of micro-scale electrically conductive elements onto microfluidic chips.

Key Skills:
modeling
manufacturing
control systems
automation


Pilot plant testing of ceramic membranes for oil-water separation

Client: ConocoPhillips

Phase: Research

Design of a testing program and procedures for analyzing various membranes considered for oil-water separation in pipeline operations.

Key Skills:
testing
analysis
modeling


Roadway-Vehicle Testing Equipment

Client: NY based startup

Phase: Equipment Fabrication

Designed and fabricated a custom testing rig to measure forces generated between a vehicle and the roadway. Test equipment was outfitted with sensors and attached to a laptop for experimental data capture. Test equipment automated for use in fatigue testing of new products under development.

Key Skills:
control system design
fabrication