A die-cast aluminium pump housing was 22% over its mass target but the tool was already cut. A new tool would have cost the programme five months.
Topology study within the existing parting line to find where material was genuinely doing no work
Correlated FEA model validated against the failed durability test before any change was proposed
Rib redistribution achievable with insert changes rather than a new tool
Vibration fatigue re-analysis demonstrating margin against the durability spectrum
Foundry trial supported on site to confirm fill and solidification
A 7-storey 1970s office block had to stay occupied through a seismic retrofit. The original drawings were incomplete, concrete strength varied by 40% between cores, and the client could not vacate more than one floor at a time.
A 42 MWp plant's provisional connection offer carried a reactive capability condition the originally specified inverters could not meet across the full voltage range. The issue surfaced three weeks before financial close.
A sterile injectable facility's Grade B suite had to hold its pressure cascade through every airlock under GMP Annex 1, with the plant room footprint already fixed at 310 m² by the building design.
