Featured Projects
EV Battery Tray for Leading Automaker
Challenge: Design a lightweight, crash-resistant battery enclosure for a new electric vehicle platform that could withstand side-impact loads while maintaining thermal management efficiency.
Solution: We engineered a multi-hollow 6082-T6 extrusion profile with integrated cooling channels, reducing the assembly from 12 individual parts to just 3 extruded components. The profile's internal ribbing provided superior crash energy absorption while the built-in cooling channels eliminated the need for separate thermal management hardware.
Solar Mounting System for 50MW Farm
Challenge: Develop cost-effective, durable mounting rails for a large-scale ground-mount solar installation that needed to withstand extreme weather conditions over a 25-year service life.
Solution: We designed custom 6005A-T6 rail profiles with integrated wire management channels and a quick-lock mounting system. The optimized cross-section reduced material usage by 18% compared to standard rails while exceeding structural requirements for wind and snow loads.
Curtain Wall System for High-Rise Tower
Challenge: Engineer a thermally broken curtain wall system meeting stringent energy codes for a 40-story commercial tower in a climate zone requiring exceptional thermal performance.
Solution: We developed custom 6063-T6 profiles with integrated polyamide thermal breaks, achieving a U-value of 1.4 W/m²K. The profile design incorporated drainage channels, gasket grooves, and structural reinforcement ribs within a slim sightline, meeting both aesthetic and performance requirements.
Automated Assembly Line Framework
Challenge: Create a modular T-slot framing system for a flexible manufacturing cell that required rapid reconfiguration to accommodate changing production line layouts without costly downtime.
Solution: We developed a series of 6061-T6 T-slot profiles with custom corner brackets and integrated cable channels. The modular system used standardized connection points allowing complete cell reconfiguration within 48 hours, compared to weeks with traditional welded steel frames.