Engineering
Beyond Boundaries.

This project originated from a critical need in high-voltage electrical field operations: workers routinely face exposure to live electrical hazards with no immediate, wearable means of real-time detection. AR Enceladus engineered a fully integrated smart safety glove from concept through to prototype-ready design.

The system embeds a compact sensing module directly onto a standard electrical safety glove. The module continuously monitors for both voltage presence and current flow, displaying real-time readings on an integrated OLED display — alerting the operative to hazard levels before contact is made. The featured unit shows a live reading of 10 mA AC with active "Voltage Detected" and "Current Warning" alerts.

Engineering scope included sensor selection and conditioning circuit design, embedded microcontroller firmware architecture, power management for battery-operated field deployment, enclosure ruggedisation for IP-rated environments, and ergonomic integration with the glove substrate. The entire solution was developed from first principles — no off-the-shelf safety module was adapted; every subsystem was purpose-engineered.

The industrial hammer mill represents a complete mechanical design and engineering CAD project executed from scratch. The client requirement was for a robust, high-throughput size-reduction machine suitable for hard mineral and agricultural material processing.

AR Enceladus developed the full mechanical assembly — encompassing the high-speed rotor and hammer configuration within the milling chamber, the heavy-duty electric motor coupled via a direct-drive shaft arrangement, and the structural welded base frame providing vibration-damped mounting. The orange-highlighted milling body and blue base plate reflect a deliberate material and finish specification developed as part of the design package.

Engineering deliverables included complete 3D CAD assembly models, detailed component drawings with GD&T tolerancing, motor sizing calculations, rotor dynamic analysis, and a bill of materials. The design was developed with manufacturability and field maintenance access as primary constraints, ensuring the machine could be serviced without specialist tooling.

This project delivered a precision engineering CAD visualisation and design package for a jacketed agitated mixing vessel, intended for controlled chemical process environments. The vessel was modelled to reflect real-world engineering constraints: pressure vessel codes, material compatibility, and hygienic or chemically resistant internal surface requirements.

The design features a top-mounted mechanical agitator drive assembly with variable speed capability, a fully-welded stainless steel pressure vessel body, external jacketing for thermal control (heating or cooling), and multiple process connection nozzles on the vessel head and body. The visualisation was produced using photorealistic 3D rendering to communicate the engineering intent clearly to non-technical stakeholders.

AR Enceladus delivered the full CAD model, cross-sectional engineering views, nozzle schedule, and preliminary heat transfer and agitator power sizing calculations as part of this engagement.

This project required the design of a compact, high-load rotational hinge mechanism capable of providing controlled angular motion across multiple stacked articulation layers. The assembly was conceived as a modular unit — allowing engineering teams to stack and reconfigure hinge layers for varying torque and angular range requirements.

The central mechanism comprises a series of precision-machined toothed disc elements providing positive location and load transfer in any rotational position. A central torque shaft locks all disc layers simultaneously, allowing the assembly to be set and clamped at any angle. The outer mounting flanges — machined from high-strength aluminium alloy with a gold anodised finish — provide the structural interface to the host assembly.

AR Enceladus developed the complete 3D CAD model, produced manufacturing drawings for each component with tight tolerancing requirements, specified the material and surface treatment schedule, and produced an assembly procedure document. The hinge design is applicable to aerospace, robotics, and industrial automation mounting systems.

This project delivered a high-fidelity, component-accurate 3D CAD model of the Digilent Zybo Z7-7020 FPGA development board. The model was developed to support downstream engineering workflows including custom enclosure design, thermal analysis, rack integration planning, and hardware documentation packages.

The Zybo Z7-7020 is a Xilinx Zynq-7000 SoC-based development platform, combining a dual-core ARM Cortex-A9 processor with Artix-7 FPGA fabric. The AR Enceladus CAD model captures all critical components to accurate geometric form: the Zynq SoC with heat-sink, DDR3 memory modules, HDMI, VGA, and USB connectors, Ethernet port, expansion headers (Pmod and XADC), push buttons, switches, LEDs, and power management circuitry.

All connectors are modelled with correct physical footprints and heights to ensure reliable clearance modelling in enclosure design and cable routing exercises. This level of PCB CAD fidelity is essential for professional hardware packaging workflows.

The quadruped robotic platform represents one of the most comprehensive mechatronic system design projects undertaken by AR Enceladus. The brief was to design a four-legged autonomous robotic system from ground up — encompassing structural mechanics, actuation, electronics, and control system architecture.

The mechanical frame features a segmented body housing electronics and power systems, with four independently articulated limbs. Each limb uses a two-degree-of-freedom configuration with high-torque brushless DC servo actuators at the hip and knee joints, providing stable locomotion across varied terrain. The design was validated through kinematic simulation and static structural analysis under worst-case loading scenarios.

The electronics architecture integrates a central processing unit for motion planning, real-time joint controllers per limb, IMU-based attitude estimation, and a power management system for battery-backed operation. The yellow and black colour scheme reflects the production-intent exterior panel design, developed in parallel with the structural frame as part of the full system visualisation package.

This project delivered a complete engineering design package for a high-performance FPV (First Person View) racing quadcopter — developed from concept through to production-ready visualisation. The design prioritises minimal aerodynamic drag, structural rigidity under high-G manoeuvring loads, and precise propulsion system sizing for competitive racing performance.

The structural frame is based on a carbon fibre composite architecture — optimised for stiffness-to-weight ratio with finite element analysis informing ply orientation and geometry. The distinctive yellow aerodynamic canopy was surface-modelled and optimised for frontal area reduction while providing full protection to electronics payload including the FPV camera. Red anodised motor mounts and ESC wiring management were designed as integral frame features.

The propulsion system was sized through thrust and efficiency analysis across a range of motor KV ratings and propeller diameters, with battery selection optimised for the power-to-weight target. Centre of gravity analysis and moment of inertia calculations were performed to define final component layout. The complete electronics integration — flight controller, ESCs, receiver, and FPV transmission chain — was laid out within the frame volume.