EnCata

Challenge

A metallurgical plant approached us regarding their Vanyukov smelting furnace. They were experiencing rapid wear of the refractory lining elements and difficulties in process control. Previously, independent experts had been consulted, but their opinions diverged, and a unified technical solution could not be formed.

Our Solution

Since real-world testing was not feasible, we created a digital model of the furnace and conducted a comprehensive simulation of thermal, hydrodynamic, and mass transfer processes. We utilized ANSYS and Simulink for this purpose. Our modeling included the formation of solid phases, overheating zones, flow velocity, and temperature in key areas.

We focused primarily on the refractory lining and gas exhaust channels, as these had the most significant impact on performance. Critical zones with crystallization processes were modeled separately to identify disruptions in heat flows. In total, we performed approximately 50 model iterations, validating our calculations against operational data and scientific sources.

To accelerate calculations without sacrificing accuracy, we employed submodeling: individual sections were calculated first, then integrated into a single, unified model.

Results

We provided the plant with a validated parametric model of the Vanyukov furnace. The production team used this model during equipment modernization, successfully improving process efficiency without rebuilding the entire furnace. The project involved considering 12 geometry variants, performing over 3,000 hours of simulation, and preparing a 200-page technical report.

Technologies Used

• Computational Fluid Dynamics (CFD)
• Finite Element Analysis (FEA)
• 3D Modeling

Challenge

The client needed an automatic irrigation and fertilization control system. Key requirements included operation in field conditions without stable mobile connectivity, online monitoring of soil parameters, and minimal equipment costs.

Our Solution

Over 8 months, we developed an MVP (Minimum Viable Product) of the system, encompassing the full cycle: design, electronics development, firmware, software, and industrial design.

The system comprises three modules:

• Analyzer: Measures humidity, pH, temperature, and ion concentration using ion-selective electrodes.
• Controller: Collects data, compares it with set parameters, and transmits commands.
• Actuator Module: Manages the supply of water and fertilizers.

For communication, we used LoRaWAN, which ensures long range and energy efficiency without requiring a mobile network. Instead of expensive modems, an RFM95 module was implemented. The server is hosted on a single-board computer within the system, allowing management via a local gateway using Wi-Fi or BLE. User access is provided through a web interface and terminal.

Results

The prototype successfully operated for a full season on an active farm. The system is fully autonomous, powered by solar energy, automatically reconnects, and notifies of low battery levels.

The Technology Readiness Level (TRL) increased from 3 to 6. The cost of the solution was reduced threefold by eliminating mobile connectivity, decreasing battery size and device dimensions, and leveraging the long range of LoRa communication. The system is ready for scaling and implementation.

Technologies Used

• LoRaWAN
• BLE (Bluetooth Low Energy)
• RFM95
• Wi-Fi
• PCB Design
• Firmware Development
• Software Development
• 3D Modeling
• Battery Management
• Solar Panels and Lithium Batteries

Challenge

In industrial and residential hot water supply systems, significant heat energy losses often occur, remaining unaccounted for due to a lack of precise measurement at the end-user level. Existing heat meters and "smart" valves couldn't provide the necessary control. Our client faced a challenge where estimated circulation losses reached up to 500% of actual consumption. This necessitated the creation of a high-precision, real-time measurement and regulation system to minimize losses and enhance efficiency.

Our Solution

We developed a comprehensive IIoT solution integrating heat metering, flow regulation, and intelligent valve control. We created a unique measurement and control technology based on scientific research in applied thermophysics and the development of algorithms derived from heat balance equations.

We designed four electronic printed circuit board assemblies (PCBAs) for controllers that interface with the heat meter via RS-485. We implemented customizable PID loops and six algorithms for control. The mechanical design of the valves was based on CFD modeling to optimize flow. To verify our solutions, we built a dedicated test stand. After successful pilot tests, the system was brought to certified mass production.

Results

The implementation of the developed IIoT system yielded excellent results: energy consumption decreased by 9.5%, and replacing outdated meters led to a 280% reduction in Capital Expenditures (CAPEX). In a city with a population of 2 million, the annual savings reached $4.2 million.

Furthermore, the system eliminated the need for regular calibration, significantly reducing operational costs and downtime. The system operates successfully in real-world conditions, confirming its effectiveness as a scalable IIoT solution built from the ground up.

Technologies Used

• STM8 MCU
• Multilayer PCBA
• PID controller
• EEPROM
• RS485
• Modbus ASCII
• C++
• C#
• Hot Water Thermodynamics
• Fluid Dynamics Simulations
• Standard metrology calibration

Challenge

The client approached us with a concept and a need to solve several problems: create a flexible cooling helmet that accommodates various head sizes and scale the system to serve two patients simultaneously. Existing solutions were limited to a single patient, making them impractical for hospital use.

Our Solution

In the first phase, we focused on optimizing the key modules of the portable cooling unit, significantly reducing its size and weight by completely redesigning the control system and compressor. This laid the foundation for future scalability.

After successful clinical trials of the single-channel version, we moved on to developing a dual-channel solution, which was crucial for expanding functionality and market opportunities. Our engineers implemented a hybrid system based on Freon and propylene glycol and integrated four PID-controlled pumps for unprecedented temperature control accuracy and overall performance enhancement.

Simultaneously, we tackled the complex task of creating a universal medical silicone helmet that ensures a perfect fit and uniform cooling for all head sizes. Using anthropometric data analysis and deformation modeling, we not only optimized the channel design but also found innovative solutions to reduce production costs by transitioning to 3-axis CNC machining and modular assembly.

Results

The device we developed is ready for operation in less than 30 minutes. It maintains a temperature from +3°C to +30°C with an accuracy of ±0.5°C. The system delivers 80 W of cooling power per channel, achieving a cooling rate of 1.0–1.5°C per hour, and can operate for up to 48 hours. Currently, the team is working on reducing the device's weight to 20 kg, integrating onboard software for diagnostics, and refining the helmet design for small-batch production and upcoming clinical trials.

Technologies Used

• Fluid Dynamics
• 3D Modeling and Assemblies
• 3D Printing
• PCB Prototypes
• Vacuum Forming
• STM32
• Injection Molding
• PID-controlled Pumps
• Freon System
• Deformation Modeling

Challenge

Our client, a B2B agritech company, faced a growing demand for simple home farming in urban environments where organic food prices are high. Existing solutions often required significant time investment or lacked innovation. The client aimed to enter new international B2C markets with a product that embodied a "plant and forget" principle and occupied minimal space. The core challenge was creating a comprehensive hardware-software B2C product that addressed these needs.

Our Solution

We conducted a comprehensive feasibility analysis (business, technology, engineering) and developed the conceptual and industrial design, including mechanical engineering and CAD. A key stage was the development of specialized electronics (PCBs) and embedded software (firmware).

The project focused on minimizing the complexity of automation and IoT while simultaneously creating an intuitive user experience and ease of maintenance. Electrical components were optimized for low power consumption. We designed a custom PCB that collects data from IoT sensors (temperature, pH, humidity, CO2, TDS solution conductivity), providing direct feedback and creating a homeostatic regulation mechanism. The system includes Wi-Fi for internet connectivity and firmware updates, as well as BLE for communication with a mobile application.

Results

Thanks to our collaboration, the client received a fully functional prototype that passed engineering validation tests (TRL-5), allowing them to proceed to further development stages, including design validation and alpha testing. EnCata provided the necessary expertise in hardware engineering, IoT, and consumer product development, enabling the client to focus on advancing their core agricultural technology.

Technologies Used

• Custom PCBA with ARM STM32
• UART
• CO2 Sensor
• Grow light LED
• Carbon air filter
• Wi-Fi
• BLE

Challenge

Traditional methods for training surgeons, which rely on theory, cadavers, or live patients, have significant limitations. They don't provide a safe environment for practicing mistakes and fail to fully prepare surgeons for the complexities of real operations. This leads to inefficient training and increased healthcare costs. The client required an innovative solution for hyper-realistic and effective surgical training.

Our Solution

We developed a hyper-realistic VR platform for surgical training, combining both software and hardware. The platform ensures maximum immersion through full-body tracking and haptic feedback, enabling collaborative surgeries and refining instrument handling skills. The key innovation is the patented MedVR Atlas technology, which provides natural interaction with the virtual world without controllers by precisely determining body position.

The development involved five stages: from industrial design to creating a dissector unit prototype and modifying it for dual-dissector simulation. We successfully overcame challenges related to achieving realistic forces and arranging components within a confined space.

Results

The result is a fully functional alpha prototype (TRL-5) of a laparoscopic simulation platform. This versatile platform is applicable in various fields, from astronaut training to neurosurgery. The physical design is optimized for high-quality VR simulation of a surgeon's workstation. We conducted 182 hours of mock-up and testing, incorporating 18 signals for precise calculation of block position and motor resistance. The modified kinematic scheme significantly reduced parasitic load on the dissector and improved working angles.

Technologies Used

• CAD Design
• 5-axis CNC Milling
• Injection Molding
• PCB Prototyping and Assembly
• Polymer Coating/Anodizing
• BOM Development

Challenge

The client faced an urgent need to create a secure electronic storage solution for Spark™ wallets within a record-short timeframe. The task was complicated by the requirement to integrate numerous components from different suppliers and coordinate three international teams.

Our Solution

Our team at EnCata developed a comprehensive engineering concept, completely redesigning the internal structure of the Piston Vault using Design for Manufacturing (DFM) and Design for Assembly (DFA) principles. This significantly simplified assembly, operation, and reduced manufacturing costs.

We took charge of managing the complex global component procurement process concurrently with prototype production. To meet tight deadlines, we made the strategic decision to begin assembling electrical components even before mechanical processing was complete, which saved 1.5 months from the overall project time. EnCata was also responsible for the final prototype assembly, integrating the work of all teams.

Results

Within 4 months, we successfully delivered a working Piston Cylinder™ prototype weighing 600 kg. This device contains 32 Piston Valve™ systems connected to 8,194 Spark™ hardware wallets. The prototype, constructed from steel and bulletproof glass, is equipped with numerous security features.

The project enabled the client to successfully present their solution at a conference, elevating the security of transactions and electronic signatures to a new level through a unique combination of hardware and blockchain technologies.

Technologies Used

• CAD Design
• BOM Development
• Triplex Curved Glass
• CNC Milling & Lathe

Challenge

The client needed a fast and safe disinfection solution for crowded public places. The main challenges involved selecting harmless disinfectant liquids, ensuring corrosion resistance of materials, and developing a system for efficiently processing a high flow of people.

Our Solution

Our team quickly mobilized all resources to create the multifunctional Gate|0 walk-through system.

We designed a modular architecture that allows for easy addition of options to the basic version and ensured exceptional structural reliability by using stainless steel. The system atomizes 15 ml of aqueous silver citrate solution through 20 low-pressure misting nozzles. A key aspect was the creation of an integrated control system based on an STM32 microcontroller running FreeRTOS, with infrared sensors for automatic passage detection and system activation. We developed a sophisticated algorithm for automatic switching between operating modes (single pass or group), visualization of disinfectant liquid levels, and voice/sound prompts, as well as a web interface for system monitoring and configuration via Wi-Fi.

Results

Within 3 months, we developed a fully functional MVP of the Gate|0 system. It features various hardware configurations, a robust casing, misting nozzles, customizable control logic, and a web interface. The system supports automatic disinfection, temperature screening (in 1 second with a thermal imaging camera), and people flow management, having undergone successful testing and being ready for production.

Technologies Used

• CAD Design
• Multilayer PCB stack
• FreeRTOS
• Wi-Fi onboard
• BOM Development
• LED Display
• Thermographic camera
• Face recognition system
• CNC Machining
• STM32
• Infrared sensors

The first affordable professional reusable medical respirator for protection against viruses and bacteria.

Imagine the only mask that not only stops the entry of pathogens into the respiratory tract, but also actively kills them.

A virus or bacteria settling along with large aerosols on the surface of a BDC-Air Cu35 primary filter (copper), as well as some viruses and smaller aerosols passing through BDC-Air Cu35 filter, meet with BDC-Air Bioactive filter and are destroyed.

Bacteria exhaled by humans do not multiply on the inner surface of the BDC-Air Cu35 fabric because a primary filter is installed which prevents the growth of bacterial colonies.

The mask is made of medical plastic with the addition of antibacterial additives that prevent the growth of bacteria on surfaces. A patch (obturator) made of soft rubber is comfortable to wear and forces any inhaled air entirely through the filter material (also made with the addition of antibacterial additives).

Challenge

In 2017, the market lacked comprehensive solutions for autonomous drone storage, charging, and transportation. The client approached EnCata with a preliminary station concept (TRL-2), aiming to create a product unmatched in complexity and automation. They required a fully autonomous system for drone takeoff, landing, and maintenance, capable of operating across a wide temperature range.

Our Solution

EnCata began with a detailed technical and functional analysis, which enabled us to develop precise specifications and prioritize features. We created a technical concept, identifying the necessary modules for the station's autonomous operation. Our solution included the development of custom electronic systems, such as a specialized charging module, control electronics, and a Battery Management System (BMS) with active cell balancing for Li-ion and Li-Poly batteries.

We implemented a high-precision mechanical system for the station's hatch operation and an automated landing platform, ensuring accurate drone positioning. For operation in extreme conditions, a custom HVAC (heating, ventilation, and air conditioning) system capable of functioning from -50°C to +60°C was integrated, along with IP-55 protection. Additionally, a weather station, GPS+GNS systems, Wi-Fi, and IR fixation technology were included for precise drone landing. Specific challenges related to achieving TRL-5 (Technology Readiness Level 5), including precision mechanics and a powerful charger (200 A peak, 500 W), were successfully overcome thanks to our expertise.

Results

The client successfully demonstrated the system, leading to the launch of small-batch production of hangars and drones. The station is versatile, suitable for numerous applications—from video surveillance to infrastructure monitoring. It accommodates drones up to 15 kg and 1400 mm in diameter, enabling up to 8 flights per day, which confirms its high efficiency and commercial value.

Technologies Used

• BMS (Li-ion and Li-Poly)
• RS485
• UART
• Wi-Fi
• GPS+GNS
• HVAC
• IR Fixation
• Milling (presumably CNC Milling based on context)

Challenge

A robotics startup needed a partner for hardware development to transform an early-stage concept of a warehouse robot (TRL-3) into a prototype ready for pilot testing.

Our Solution

EnCata acted as the contractor, executing a full cycle of hardware development. We started by refining the mechanical concept and industrial design, incorporating Design for Manufacturing (DFM) principles. Kinematic simulations were performed to ensure robot stability, especially under uneven loads. We optimized the electrical components, manufactured and tested the prototype, and prepared complete documentation for mass production. A particular challenge—stability under asymmetrical loading—was addressed through early kinematic modeling.

Results

We helped the startup transform their initial concept into a fully functional working prototype (TRL-8), ready for pilot production. A physical robot was created in just 5 months, allowing the client to focus on software development and system integration. The robot can transport up to 400 kg and has an IP-45 rating, ensuring reliable operation even in the rain.

Technologies Used

• Wireless battery charger design
• DC motor wheel
• CNC milling & lathe
• Laser cutting CNC
• Kinematic simulations
• Welding
• Lidar
• Vacuum forming
• Video camera for MV (Machine Vision)
• Sheet metal bending CNC

Challenge

A startup specializing in educational robotics platforms approached EnCata with a working prototype of a humanoid robot at an early development stage (Technology Readiness Level 3). The main objective was to give the robot an appealing aesthetic and enable it to perform human-like movements, all while minimizing the cost of all materials and components. The priority was the robot's appearance, which needed to look attractive and modern for school and university students.

Our Solution

EnCata developed a technical concept and industrial design, optimizing the robot's dimensions and functionality to reduce costs. The proposed all-metal frame with vacuum-formed plastic casing allowed us to cut manufacturing expenses by 70%. We designed a 4-finger gripper for simple tasks and conducted motion simulations and load analysis. We created a Printed Circuit Board Assembly (PCBA) for motors and servo drives, using a Raspberry Pi as the main board. EnCata was responsible for optimizing the Bill of Materials (BOM) and procuring components. After CAD design, a prototype was created for Engineering Verification Testing (EVT). Plastic covers were produced using 3D printing and vacuum forming. Following successful Design Verification Testing (DVT), CAD models were updated, and EnCata prepared a complete package of manufacturing documentation.

Results

We elevated the project's Technology Readiness Level from 3 to 8 (EVT and DVT), providing the client with a tested prototype and a complete package of manufacturing documentation for mass production. This resulted in a 70% reduction in manufacturing costs, with the cost of custom components in the BOM totaling $950. The robot is actively used in schools and colleges for teaching robotics and programming.

Technologies Used

• Raspberry Pi
• CMOS Cameras
• Custom PCBA IC design
• CNC Milling & Lathe
• Laser Cutting CNC
• Sheet Metal Bending CNC
• Welding
• Vacuum Forming
• Electrochemical Steel Anodizing
• Custom Jig for Assembly

Challenge

The client's main task was to transform a working prototype (TRL-4) of a hardware 3D body scanner into a product ready for mass production. Their core business is developing AR software for the fashion industry, and they aimed to focus all their internal resources on that. Therefore, they needed a partnership for the engineering refinement and preparation of the hardware scanner for scaling.

Our Solution

EnCata developed the engineering concept, custom PCB, and industrial design for the scanner. We considered all user factors, from safety and interface convenience to manufacturability. The prototype successfully passed EVT (Engineering Verification Testing) and DVT (Design Verification Testing), confirming its readiness for mass production (TRL-8). For the casing, we used composite sheet aluminum, ensuring a lightweight and stylish appearance, which, combined with aluminum profiles, provided rigidity and safety. A stepper motor with a ball screw drive guaranteed smooth and silent scanner movement.

Results

Upon project completion, the client received a complete package of design documentation and a prototype at TRL-6/7, fully ready for further development. Successful design validation and field user trials confirmed the product's readiness for mass production (TRL-8). The final device can scan objects and people up to 2.5 meters in height while weighing only 42 kg, reflecting an optimal balance of functionality and design solutions.

Technologies Used

• Vacuum Forming
• Wi-Fi
• STM32
• RS485
• C++ / C#

Challenge

An inventor approached EnCata with an ambitious and patented idea: to create a new type of frictionless transmission capable of transferring high torque without using a clutch. The main difficulty was that this innovative concept existed only on paper – there was no working variator prototype, meaning the viability and functionality of the idea itself remained unconfirmed. The client needed more than just a design; they required a proof of concept and technology in the form of a real, working demonstration prototype.

Our Solution

We assessed the initial TRL of the "variator" as TRL-2. During the preparation of the CAD model for production, it became clear that the original design would not be functional and would not demonstrate the stated principle. Given the goal of creating a working prototype, we proposed to completely redesign the variator from scratch. The project followed EnCata's standard process: we developed a new technical concept, performed kinematic simulations and calculations to create a new 3D CAD model. Then, documentation for prototype production was prepared. The manufacturing of the variator's precision gears required CNC milling, electrical discharge machining (EDM), and annealing. The entire production process, including assembly, took 4 weeks. After prototype fabrication, we conducted tests and updated the 2D drawings and BOM.

Results

EnCata invented a number of patentable solutions, which were transferred to the client, a standard company policy. This enabled the client to approach automotive companies seeking new, reliable transmissions. As a result of EnCata's work, 3 patents were obtained. The variator design consisted of 117 parts. A 5-fold increase in cable travel was achieved thanks to the new pulley groove design. The Technology Readiness Level (TRL) was raised from 2 to 4, and the total project duration was 5 months.

Technologies Used

• CAD Design
• Hydraulics Design
• Kinematic Simulations
• CNC Laser Cutting
• CNC Metal Bending
• CNC Milling
• CNC Plasma Cutting
• MIG and TIG Welding
• Steel Honing

Challenge

A consumer electronics startup needed to develop a multifunctional smart device for air quality improvement, combining purification, humidification, ionization, aroma diffusion, and monitoring features, all controllable via a mobile application. The main development tasks included integrating five functions into a compact, quiet, and energy-efficient device. For proper operation, we had to ensure sensor reading accuracy and develop reliable firmware. To successfully meet business objectives, we performed rapid prototyping to test hypotheses with focus groups and engineered the product for mass manufacturability.

Our Solution

We developed the electronics based on an STM32 microcontroller to control the fan, ultrasonic humidifier, ionizer, and an array of sensors (temperature, humidity, CO2 concentration, water level). We ensured a low noise level (40 dB in night mode) and optimal power consumption (40 W peak) from the AC adapter.

The developed mobile application provides full control over the device's functions and air quality monitoring. The application uses BLE (Bluetooth Low Energy) for data transfer to the cloud via a smartphone gateway and supports integration with smart home systems (Alexa, Siri, Alisa, Google Home, IFTTT).

Results

The project was executed from concept to crowdfunding and production readiness in 9 months (6 months for hardware, 3 months for application development). The startup successfully launched two crowdfunding campaigns on Kickstarter and IndieGoGo, which led to mass production in China with an OEM manufacturer for the US and EU markets. The product is currently sold online and on Amazon and AliExpress platforms.

Technologies Used

• CO2 Sensor
• Bluetooth Low Energy (BLE)
• Embedded Wi-Fi
• Custom AC-DC Adapter
• Temperature Sensor
• STM32 Microcontroller
• Ultrasonic Mist Generator/Humidifier
• HEPA Air Filtration
• Air Ionization

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Challenge

A startup tasked us with developing a multifunctional smart kettle with precise water temperature control for baby formula and hot beverages. Key requirements included heating and maintaining temperature, as well as cooling from 100°C to 38°C within 1-2 minutes, which is critical for infant nutrition.

Our Solution

We conducted a techno-economic analysis and defined use cases, proposing IoT integration and a mobile application for remote control.

The comprehensive work included industrial design, electronics and firmware development, CAD design, rapid prototyping, and Design for Manufacturability (DFM).

During the development, we applied TRIZ/TIPS analysis to find a technical solution for rapid water cooling. As a result, we implemented air sparging technology. Five unique Printed Circuit Boards (PCBs) were designed, subsequently patented by the client. Additionally, a proprietary compressor, powered by a lithium-ion battery, was developed.

Results

The client received a product fully ready for production, which successfully launched on the Kickstarter platform. We provided a complete development cycle—from concept to a ready engineering solution and all necessary documentation for mass production launch.

Technologies Used

• STM32
• Bluetooth Low Energy (BLE)
• Wi-Fi
• Angular
• Ionic
• Wireless Charging