Case studies

Parts we were asked to make because the obvious route did not work. Each case sets out the problem, why this process was the one that solved it, and what the finished part measures.

CNC machining

CAD model

CNC milling · one-off, four-day turnaround

CubeSat structure

Structural frame for a microsatellite, machined as a weekend one-off. The satellite reached orbit in 2016.

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Machined copper part: a disc with a dense outer ring of radial fins and a radial vane structure around the centre.

CNC milling · copper · two setups

Magnetron component

Copper component of a magnetron for an advanced microwave device.

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CNC machining · CMSX-10 single-crystal superalloy

Turbine blades

Blades for a combined heat and power plant turbine.

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3D printing

3D-printed PA6-CF vortex gripper body with a brass G 1/8-inch fitting and external spiral air channels

Engineering problem · FDM, no moving parts

VG-90 non-contact vortex gripper

Lifting 110 °C glass bottles straight off the annealing lehr without touching them — one printed part, no moving parts.

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3D-printed vibration-isolating sensor mount with an X-braced truss column and a copper-lined M20 boss

Problem · FDM, no moving parts

Vibration-isolating mount for a pressure sensor

A pressure sensor shaking itself apart on a pump housing — isolated where it sits, instead of moved somewhere quieter.

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3D-printed sensor retrofit bracket with an orange datum ring and an angled sensor head

FDM · PC-CF · no moving parts

Vibration-sensor adapter bracket for a pump retrofit

A vibration sensor that had to meet a pump housing it was never designed to fit — and stay clear of the diagnostic band.

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Published with our customers' permission.

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