Each project below is a real engineering challenge — with a documented problem, findings, and outcome. Each card links to a highlights summary; the full engineering report is available as a PDF download.
Cast aluminum inserts kept breaking under normal tightening loads. We traced the root cause, evaluated material alternatives, and recommended a fix that had the potential to eliminate a five-figure annual expense.
$25,000+
Annual Cost Saved
2.4×
Strength Increase
21 in-lbs
Failure Load
A facility needed to increase production but didn't know if the largest off-the-shelf chain tensioner could handle the load. We translated production variables into an engineering load case, ran FEA, and confirmed a 2.0 safety factor at the target rate.
2.0×
Min. Safety Factor
180 lbf
Tensioner Load
2 parts/sec
Production Rate
A pneumatic gripper was proposed for a new assembly line application using preferred ABS plastic components. No engineering data confirmed whether the design could handle the loads or what air pressure was safe. FEA revealed geometry — not just material — was the limiting constraint, and a redesigned aluminum gripper arm was validated before a single component was ordered.
$33,300
Trial-and-Error Cost Avoided
30–35 psig
Recommended Pressure
85 psig
Max Validated Limit