Aerospace Systems

Overview

Collaborated with a US-based startup to design a cost-efficient coaxial helicopter. This project involved developing the helicopter from the ground up, ensuring it met stringent requirements for thermal management, weight optimization, and thrust performance.

Key Features

• 2.5 kg weight budget.
• Designed to operate in harsh temperature requirements. (20°C (-4°F) near the equator but can reach up to 20°C (68°F)
• Designed a printed circuit board (PCB) to integrate and manage all critical flight sensors and data logging.

Overview

Worked with an individual client to design upgradeable features for their off-road buggy, including a complete redesign of the assembly in CAD. Delivered detailed engineering drawings for critical components and facilitated collaboration with industry partners to manufacture and ship the upgraded parts to the client.

Key Features

• Driver weight up to 100kg, providing calculations for component sizing.
• Customizable wheel suspension
• Provided new drive shaft engineering drawings and full set of custom components.
• Tested components functionality.

Mechanical System Design

Robotic Automation

Overview

Designed an initial prototype for an alternative door opener for a large automation company, including the selection of sensors, motors, and electronics. Developed preliminary software to operate the prototype for internal review.

Key Features

• Capable of operating household doors weighing up to 20 kg.
• 5 second door opening time, designed for 100,000 door cycles.
• Provided complete embedded software package.

Overview

We specialize in boutique, specialized machinery. This project involved designing a prototype for mass-manufacturable smart blinds and curtain openers. The client aims to produce 100,000 units for market entry in 2025.

Key Features

• Operates on a 5V/12V DC power supply, with an low power consumption to be powered be small solar units.
• Adjustable chain holder.
• Provided complete embedded software solutions.

Special Purpose Machinery

Software and Databases Solutions

Overview

Stellar Forged also specializes in cloud computing services. We can seamlessly migrate your legacy infrastructure to modern cloud providers. Cloud computing offers your company peace of mind, ensuring that your local servers are no longer a single point of failure and minimizing the risk of downtime.

Key Features

• Utilization of Lift-and-Shift, Replatforming, or Refactoring strategies based on the client’s legacy system.
• Migrating to tools like AWS Migration Hub, Azure Migrate, or Google Cloud Migrate to streamline the migration process.
• Automated backup solutions using tools like AWS Backup, Azure Site Recovery, or Google Backup and DR.

Overview

We provide comprehensive manufacturing support, including creating detailed engineering drawings, resolving issue ticket backlogs, and generating tailored work orders. Our services also include designing and manufacturing custom tooling, such as jigs and fixtures, to enhance precision and streamline production workflows.

Key Features

• Engineering drawings, we have ISO GPS and ASME GD&T-trained engineers.
• Help solving your Issue ticket backlog.
• Implementing Enterprise Resource Planning (ERP) software and creating detailed work orders to streamline operations and enhance workflow efficiency.
• Designing tooling jigs and fixtures.

Manufacturing Support