Services
Development, prototypes and documentation for battery systems, drones and other electromechanical products. One team for the structure, the electronics and the battery, so they fit together the first time.
Battery systems
Battery packs from cell selection to the finished prototype: cell holders, busbars and terminals, fusing, BMS integration and the housing. We test cells ourselves and spot-weld prototype packs in-house, so a first pack does not wait for a supplier.
- Cylindrical 21700 packs, built so far from 14S to 24S
- Busbar and terminal design for spot welding
- BMS integration, precharge and contactor control
- Stationary storage from second-life EV modules
Drone airframes and integration
Heavy-lift multirotor frames from tubes, carbon sandwich plates and machined adapters. Motors, batteries, avionics and the harness are placed in the same CAD, so mass, cable lengths and clearances are known before anything is ordered.
- Frame layout and FEM checks
- Motor, ESC and battery integration
- Harness routing and cable drawings
- Landing gear and payload mounts
PCB design
Most products need mechanics, electronics and software to work together. We design the boards in KiCad, from high-current power distribution to CAN interfaces, and order them assembled with parts the factory keeps in stock.
- Power distribution and precharge circuits
- CAN and DroneCAN interfaces
- Flight-controller carrier boards
- Production files and BOMs
Testing and simulation
Finite element analysis and thermal imaging find problems before the hardware does. For propulsion we measure on our own thrust stand, and battery packs go through charge and discharge tests before they fly.
- FEM of frames and brackets
- Thermal imaging under load
- Thrust stand for motor and propeller combinations
- Cell and pack capacity tests
Prototyping
Fast prototypes from our own printers and CNC router, and laser-cut sheet metal and tubes through partners. Parts that only exist physically are 3D-scanned and redrawn.
- FDM printing, PETG-CF for structural parts
- CNC routing of plates and sandwich panels
- Laser-cut sheet metal and tubes
- 3D scanning and reverse engineering
Documentation and build guides
Drawings, parts lists with order numbers, sourcing and assembly instructions. When a project is open, it becomes a web build guide like the ones for Caribou and Longshot.
- Part, cable and assembly drawings
- Parts lists with suppliers in the US and the EU
- Interactive 3D build guides
How a project runs
Short loops between design and test. You see the CAD, the boards and the test results as they happen.
Requirements
What it has to do, weigh and cost, and what it connects to.
Design
CAD and electronics together, with mass and cost tracked from the start.
Prototype
Built in-house where possible: printing, welding, CNC, assembly.
Test
On the bench, on the thrust stand, in the air.
Document
Drawings, parts lists and a build guide others can follow.