Surgical Mask Packaging Automation System
Re:Build DAPR developed a custom automation system that transformed a manual surgical mask packaging process into a fully integrated high-speed production solution. By combining precision product handling, servo-driven packaging, and seamless machine-to-machine integration, the system enabled packaging rates of up to 100 masks per minute while improving efficiency, reducing labor requirements, and supporting scalable medical device manufacturing.
High-Temperature Superconductor Cable Production System
Re:Build DAPR developed a custom automation system that transformed a manual high-temperature superconductor (HTS) cable manufacturing process into a scalable production platform. By integrating precision tension control, automated bundling and spiral wrapping, and advanced particulate mitigation systems, the solution improved cable quality, increased manufacturing capacity, and enabled production of HTS cable assemblies up to 200 meters in length.
High-Speed Media Transport System
Re:Build DAPR developed a custom high-speed vacuum transport system for a next-generation industrial printing platform, enabling reliable handling of diverse media types at speeds up to 150 meters per minute. Through advanced media handling engineering, vacuum system design, and structural analysis, the solution provided a scalable foundation for future printer development while supporting a successful product launch at one of the industry’s most important global trade shows.
Precision Micrometer Assembly Automation System
Re:Build DAPR developed a fully automated assembly system for a leading precision measurement tool manufacturer, transforming a highly skilled manual micrometer assembly process into a repeatable, recipe-driven production platform. By combining robotics, precision motion control, automated cleaning, and proprietary thread-alignment technology, the system improved product consistency, reduced reliance on specialized labor, and created a scalable foundation for future manufacturing growth.
Mini Putt Engineering Challenge
What happens when engineers are challenged to reinvent mini golf? At Re DAPR’s first-ever Mini Putt Engineering Challenge, nine teams designed and built unique holes featuring automation, robotics, pneumatics, computer vision, and creative mechanical systems. Take a behind-the-scenes look at the engineering innovation that transformed a simple game into an interactive technical showcase.
Carbon Capture Process Development & Automated Testing Platform
Re:Build DAPR partnered with Heirloom Carbon to develop an automated testing platform that accelerated the development of direct air carbon capture technology. The system increased testing throughput, improved process repeatability, and enabled rapid evaluation of multiple carbon capture variables, helping advance the technology from laboratory research toward commercial-scale deployment.
When Manual Precision Reaches Its Limit: Automating Capsule Fill and Seal at Scale
Re:Build DAPR helped a growing cosmetics manufacturer move beyond the limits of manual capsule production by engineering a fully automated fill and seal system. By integrating precision fluid dispensing, redesigned foil sealing, and machine vision inspection, the team increased throughput while improving consistency and product quality. This post explores how thoughtful system architecture and early engineering validation can transform a labor-intensive process into a scalable manufacturing operation.
When the Floor Plan Becomes the Bottleneck: Rethinking Scale in Biotech Automation
Re:Build DAPR solved a complex biotech scale-up challenge by treating the building itself as part of the automation system. By integrating vertical motion, containment, and precision automation, the team enabled two physically separated lab spaces to function as a single high-throughput line without compromising biosafety. This post explores how systems-level engineering can unlock capacity when floorplans, not equipment, become the limiting factor.
Designing a Lean Battery Assembly Line Using 3P
Re:Build DAPR applied Lean’s Production Preparation Process (3P) to design a safer, more scalable battery assembly line before equipment was finalized. By using hands-on simulations, mockups, and rapid experiments, the team reduced risk, improved ergonomics, and aligned the line to aggressive production targets. This post explores how early Lean thinking leads to smarter equipment design and stronger manufacturing performance.
Engineering an Automated Battery Cell Sorter for Speed and Insight
Building effective battery automation requires thoughtful system architecture, not just fast hardware integration. Learn how Re:Build DAPR designed an automated cell inspection platform that blends robotics, machine vision, and real-time analytics. The system demonstrates how targeted automation can unlock major efficiency gains.