Portfolio #

Engineering #

Design review of wearable device #

Year: 2024
Client: design studio, large OEM
Work: design review, tolerance stack-up analysis, production drawings

Pilotfish, a design studio, was involved in the design of a wearable device for a well-known electronics manufacturer. They approached us to review the mechanical design of a complicated optical assembly critical to the functionality of the device.

We conducted a detailed 3D tolerance stack-up analysis, which identified some issues. We helped the client and their suppliers to understand their precision requirements better, and to modify the design to ensure functionality.

We also produced 100+ pages of production drawings for the first small batch production of the device. The drawings were delivered on a very tight schedule to meet the client's milestones.

Prototype Computer Vision System for Precision Agriculture #

Year: 2022
Client: early stage startup
Work: computer vision, IoT, software, mechanical design, electronics

The client, an early-stage tech startup, is developing a computer-vision based solution for monitoring of items in manufacturing. They required a special type of camera system for in-field monitoring. They couldn't source a solution on the market, so they turned to us to build it from scratch.

We built a small team composed of a mechanical, electronics, and software engineers. We tested multiple camera types on site, identified one which met the client's specification, and then proceeded to build an IoT system around it.

The camera needed to operate autonomously, without external power or data connections, in a difficult environment. We designed the power electronics, enclosure, and mounting. We wrote the firmware to process photos on device, and software to manage a fleet of cameras, integrated with the client's infrastructure. The system was solar powered, with its own mobile connection, rugged enough to withstand years of field use.

We produced the first prototype, along with documentation which allowed the client to make more as needed.

Pilot production system for branding sustainable single-use packaging #

Year: 2021
Client: Early Stage Startup
Work: R&D, production jigs, production machinery

GaeaStar has developed a novel sustainable packaging solution. They were looking for a system to brand and customise items for their clients. In line with their commitment to 100% sustainability, their brief called for a machine which would brand hundreds of items per day without consuming any plastics. This meant that typical packaging branding methods, based on polymer inks, were out of the question.

We identified three possible solutions to this problem, and built prototypes to test them. We then let the client choose which one they liked the most. We perfected the chosen process in collaboration with the client's designers to match the client's aesthetic. Finally, we built a machine and production jigs which implemented the process, and helped the client integrate it into their pilot production facility.

R&D for an automated electronics repair solution #

Year: 2021
Client: early stage startup
Work: R&D

The client, an early-stage startup, had an idea for a novel repair process for consumer electronics. We conducted a literature review and expert interviews to document state of the art repair techniques, and assess the feasibility of the client's approach. We also carried out first benchtop experiments. Our work formed the basis of the client's subsequent R&D efforts.

Improved face mask concept #

Year: 2020
Client: early stage startup
Work: R&D, literature research, prototyping

Undead was a startup formed during the 2020 Coronavirus pandemic to develop a better face mask. They had a list of things they wanted to improve on versus commercial designs. We carried out literature research to identify which were possible and which were not. Then we built a modular prototyping mask platform which allowed Undead to test different ideas as modules. We built a number of prototype units, which were used in fundraising and client communications. We also created renders and videos showcasing the platform.

Commercial #

Industrial Heat Pump Market Study #

Year: 2024
Client: early stage Startup
Work: market research, business development

SynchroStor, a seed-stage startup, have developed a novel compressor technology for an energy storage application. The same technology could be used for decarbonising industrial heat. They approached us to help them evaluate the business opportunity in the heat sector.

We carried out detailed market research to position the company within the heat pump industry. Then, we conducted an extensive review of scientific and industry literature to identify niches for which their technology was best suited. We analysed the two most promising industry sectors in detail, and produced materials to help them approach potential clients in those sectors.

German Electricity Market Reform Policy Study #

year: 2024
client: business developer
work: policy analysis

The client, a UK-based business developer focused on the energy transition, wanted to understand changes to the German electricity market due to take place in 2024-2027. We provided a detailed analysis of the situation, based largely on a whitepaper released by the German government. We placed the reform in the broader scope of the EU electricity markets, and explained how it will impact a particular business opportunity that the client was exploring. We created written materials and graphics that concisely represented the topic.

Techno-economic analysis of a large-scale renewable heating system #

year: 2023
client: internal
work: techno-economic analysis, literature research, expert interviews

One of our core competencies is a detailed understanding of the decarbonisation of low-temperature heat. A big issue in this field, largely unaddressed today, is how we will provide carbon-neutral heat to cities in Central Europe, in the depth of winter, when solar PV output goes down to almost nothing. Many proposed solutions to this problem are not cost-competitive with gas heating, and therefore unlikely to be adopted by the market. We carried out a detailed study of a concept which integrated the cheapest source of thermal energy - solar PV run through a heat pump - with the cheapest form of energy storage - pit thermal energy storage. With storage so cheap (30cts/kWh), it is possible to store heat seasonally, from summer to winter, which enables using solar PV for heating.

We built a dynamic model of the system to prove performance under conservative assumptions, and a detailed financial model to assess project economics. We found that it could deliver levelised cost of heat on par with natural gas. We wrote a short whitepaper on the topic.