Hardware Development Services
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Projects

We’ve seen a thing or three.


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BioSolids Dryer

The City of Kingston, NY, partnered with V1 team members, succeeded in developing a new and innovative system for managing wastewater treatment plant solids residuals in an economical and environmentally sound manner. The first system of its kind in the world has successfully been in operation at the Kingston Wastewater Treatment Plant since April 2007. Waste biogas is captured from the plant's digesters and utilized as the only required fuel to turn 10 wet tons per day of municipal wastewater sludge into two tons per day of an EPA recognized "Class A" EQ pelletized usable biosolid.

The drying technology selected was previously proven in large scale dryers in Brugges and Antwerp, Belgium, and in Baltimore, Maryland. V1 team members initiated an energy evaluation of the overall plant operations and integrated this solution to the existing plant. The entire system then needed to be scaled down to meet the needs of the smaller Kingston operation. The operating system also needed to be updated to allow for automated operations. Since startup, the plant has hosted many tours of the new operational model.

Measurable environmental benefits of this innovative project include:
• Removing a 6-8 ft. high arc burning methane, sulfur and mercaptan compounds. Biogas is now burned in a furnace and used as a heat source for the drying process;
• Reducing tens of thousands of yards or tons of "Class B" waste solids from being landfilled annually;
• Reducing truck traffic by 70 trips per year;

Key Skills:
scouting, problem/need identification
market analysis
technology development
industrial innovation
proof of concept testing
business creation
legal
permitting
fundraising
technology design
sales and marketing
public/private partnership building
construction
operation and maintenance


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Landfill Gas Control

Design and prototype development of a wireless monitoring and control system for landfill well gas collection system. Design included innovative sensor implementations, and advanced wireless mesh implementation, with innovative modeling of the landfill gas production process.

Key Skills:
modeling
sensor systems
non-metal fabrication
wireless technology


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Energy Harvesting

Designed system for harvesting energy from braking vehicles on roadways. Product designed to be self-powered, wireless, and integrated with remote data acquisition and realtime cloud based visualization. Fabricated early proof of concept designs, iterated on promising solution, and and fielded a demonstration unit in upstate NY. 

Key Skills:
technology design
technology development
proof of concept testing
modeling
fabrication
energy generation
sensor and parts integration
wireless communication


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Microfluidics Manufacturing

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


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Microcontact Printing

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


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Roadway-Vehicle Interface Testing Equipment

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


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Automotive

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


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Wearable Enclosure

Design and rapid prototyping of a wrist mounted enclosure to fit existing PCB components. Iterations of design based on user feedback.


MicroFluidics Connector

  • PDMS mold design using solidworks, 3-D printer, and ultimately machining plastic stock.

  • Corona Wand treatment to adhere PDMS to microfluidic chip.

  • Hypodermic needle cast into the PDMS mold


Turbine Design

  • Designed different 8” diameter turbine blades to maximize efficiency with the amount of water flow and velocity available.

  • Turbines were 3-D printed and tested before being made from a stronger material.


Plasma Gasifier

Client: Spec
Phase: Concept

Design of a universal waste processing system for big-box retail stores, to move toward the zero-fuel, and zero-waste goals of large retailers

Key Skills:
energy systems
fabrication


Plastic packing materials for CO2 capture

Client: ConocoPhillips
Phase: Research

Research into efficiency of various materials considered for CO2 capture from amine scrubbing systems.

Key Skills:
chemical engineering
modeling
prototype development


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


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

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Pumping Calculation Tool

Development of custom tool for theoretical evaluation of pumping scenarios. Iteration based on customer feedback and requirements.

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Automotive Manifold Adapter

  • T3 Turbo Flange adapter, designed to clock the turbo 12 degrees counter-clockwise on a specific forge designed manifold. Final adapter design would be forged as well.

  • Bolt on or weld on designs available


Orifice Plate Testing

  • Five different orifice plate designs

  • Calculating and Machining data collection ports

  • HDPE Melting assembly procedure to connect pipes to orifice plate union


Microturbine Cogeneration

Client: Spec
Phase: Concept

Design of small scale turbine generation and cogeneration for distributed electric generation at the household level

Key Skills:
energy systems
turbines
cogeneration


Electrowetting-driven thermal management

Client: Spec
Phase: Concept

Design and early analysis of the potential for electrowetting techniques to be used for improving the heat transfer capacity of heat-pipes.

Key Skills:
modeling
electronic design
control systems


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


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

Controlled Painting Environment for Boeing Aircraft

Created a micro environmental chamber to seal against an airplane and cure paint. Discover and designed the systems to maintain temperature, humidity, and air velocity in an environment within specifications. Developed the logic and control system using PLC and off the shelf interface parts.


Thermo-hydraulic test cell for heat-pipes

Client: CRS Engineering
Phase: Pilot

Design and fabrication of a test cell for evaluation of laboratory-scale optimization of heat-pipe wicking elements.

Key Skills:
modeling
fabrication
control systems


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


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


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


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


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