Automated Electrical Compound Application System
Re:Build DAPR designed and built a high-throughput automated coating system for electrical compression connectors, replacing a maintenance-intensive manual process with precision adhesive application, electromagnetic compound deposition, and automated inspection. The system achieved 3,600 parts per hour while dramatically reducing cleanup time, maintenance requirements, and production downtime.
Anode Manufacturing Scale-Up System
Re:Build DAPR partnered with a leading energy storage technology company to scale a novel iron anode manufacturing process from laboratory-level production to pilot-scale output. By integrating refurbished and custom-engineered equipment, advanced thermal analysis, high-temperature material handling, and upgraded process controls, the solution increased production capacity by approximately 1,200% while improving safety, ergonomics, and manufacturing efficiency.
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.
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.
OEM 3D Printer Development
Re:Build DAPR Engineering combined sound engineering principles, innovative design approach, and solution-based processes to develop a first-generation metal 3D inkjet printing machine. The fast-track project met an accelerated schedule to deliver an alpha machine for introduction at a key industry tradeshow.
Fuel Cell Assembly Automation
Re:Build DAPR Engineering combined sound engineering principles, innovative design approaches, and solution-based processes to design a custom automated material handling machine. The automated machine was successful at destacking a single layer of a porous fuel cell material and transporting the material for testing at high speeds without damage.
Automated Punch Press
Re:Build DAPR was able to utilize sound engineering principles combined with a collaborative and creative design approach to develop an Automated Punch Press machine that seamlessly integrated old, outdated technology with new. The machine was successful at isolating raw material, processing and neatly stacking each extrusion.