Engineering in practice
A look at real projects — the challenges, the approach, and the outcomes. Details are shared with client approval; proprietary information is withheld.
4U Server Expansion Chassis
Client: Hyperscale OEM (Confidential) · On-site & Remote Engagement
The Challenge
A hyperscale OEM needed a 4U server expansion chassis validated for deployment in coastal data center environments. The design had to meet strict thermal performance targets while surviving vibration profiles characteristic of installations near marine environments — salt air, humidity swings, and continuous low-frequency mechanical input from building HVAC systems and external sources.
The Approach
Full 3D CAD modeling in SolidWorks established the geometric baseline. Structural finite element analysis was run against the coastal vibration profile to validate fastener loads, panel stiffness, and bracket fatigue margins. Thermal simulation characterized the internal airflow paths and identified hot spot risks at target power densities, driving vent geometry and baffle placement decisions prior to first-article build.
The Outcome
The chassis design was validated to the 75°C thermal target under full load, with structural analysis confirming sufficient margin across the coastal vibration spectrum. Simulation-driven design changes reduced the number of prototype build iterations required, compressing the schedule and lowering program cost. The validated design proceeded to production.
Additional case studies are in preparation
We're actively expanding this section. Projects covering industrial IoT enclosures and harsh-environment compute systems will be added as client approvals are finalized.