“Please note: Specific technical details of this project are intentionally omitted to respect confidentiality and security requirements. The description focuses on the overarching challenges and approach without disclosing sensitive information.”

Customer Challenge

Extreme operational conditions in global security, demanded materials that could endure high stress, corrosion, and environmental exposure while meeting stringent compliance and durability standards. Selecting the optimal balance of lightweight and robust materials is essential for mission critical applications, ensuring performance and availability without compromising lifecycle durability.

Result

A scalable DOE test production line was developed and built, to systematically investigate and optimize light weight materials characteristics. This DOE-line enables structured experimentation, rapid iteration, and validation of process parameters, ensuring continuous improvement and future proofing for evolving operational demands.

Applied Technology

The core focus was on translating materials characteristics into process requirements into a new fusioncore concept. This involved systems engineering, material selection, and ergonomics, combined with strict adherence to Safety, Health, and Environment (SHE) standards. The design ensures compliance with all relevant regulations while delivering a secure and efficient platform for sensitive operations.

TSG Contribution

TSG Group led the end to end effort: we engineered the core system, developed and built the DOE test production line. Our multidisciplinary team integrated mechanical, electronic, and software components; established rigorous test protocols to characterize materials; and ensured compliance with applicable military standards.