Mechanical Superiority

Work

Air Force travel pods

EhPro Custom Fabrication in Texas had a pre-existing product that they needed models and shop drawings for. Mechanical Superiority took one of their prototypes, measured it in Colorado, and generated CAD models. Not only did this allow EhPro to get their design approved by the Air Force, but it also enabled them to upgrade to more efficient CNC manufacturing.

Reverse engineering and production, with EhPro

Air Force travel pods

  • The projectWhen a fighter jet needs to deploy or go somewhere for training, there is an extensive list of things that need to go with it: toolboxes, equipment, luggage, etc... The maintenance crews pack much of these items into Travel Pods to make sure that it all goes with the jet. EhPro has decades of experience refurbishing used Travel Pods and knows them inside and out. But when an opportunity came along to build brand new ones from scratch, it came with a requirement for CAD models and shop drawings so that the details of the construction could be confirmed and analyzed by the Air Force. At the time EhPro had no in-house CAD capabilities. So they turned to Mechanical Superiority for help, and a harmonious partnership was born.
  • The resultsA prototype pod was shipped to Mechanical Superiority in Colorado, and the pod was measured extensively, with minimal disassembly as-required. Combined with remote communication (including some emailed hand drawings back and forth), this process yielded accurate CAD models and assembly, and a full set of construction-ready shop drawings for EhPro. The customer was extremely satisfied with the quality and usability of the shop drawings, and the Air Force got the CAD models they needed to confirm and approve the design so that the customer could massively upgrade their product line. The CAD models also allowed EhPro to upgrade their manufacturing capacity: With the support of Mechanical Superiority's CAD/CAM capability, EhPro decided to acquire a Haas CNC Gantry mill so that the major components of the pods could be made with substantially increased precision. The result has been a radical reduction in the unit production time of the pods, as well as a better-looking and more consistent end product. Mechanical Superiority is now partnered with EhPro and also assists in the construction of the pods (riveting and TIG welding of the main bodies). At risk of understatement: Not many engineering partners bring this much to the table.
  • YearOngoing
Model CAD assembly of a riveted aluminum travel pod
What was drawn
Built Mark standing beside pod number 001, his first completed travel pod, in the shop
What was built
1 CAD assembly of a riveted aluminum travel pod
2 Mark beside pod number 001 in the shop
3 Freshly painted travel pods lined up on a hangar floor, in blue, green, and black and yellow checks
4 An F-16 in a shelter with a travel pod on the ground beside it, ready to load
5 A Thunderbirds F-16 with a travel pod painted red, white and blue under its wing

Some of the pods are painted for their squadrons, and some for the USAF Thunderbirds.

More work

CAD model of the drive-side brake adapter Two machined aluminum brake adapters

Bicycle brake adapters

Remote CAD and rapid prototyping.

CAD layout of six cloud signs, numbered one to six Mark in the shop holding two finished aluminum clouds

Aluminum cloud signs

Aluminum fabrication with an artistic element.

Annotated CAD model of the tractor's aluminum roof frame The finished Ford 641 with its aluminum frame and white canvas top

Ford 641 tractor frame

Aluminum tube frame with a canvas top.

CAD model of the topsoil screener: a tilted screen deck on springs over a steel base The screener's steel frame standing in the shop

Topsoil screener

Industrial machinery, designed and built.

CAD model of a rear control arm with spherical bearings at each end Two machined control arms on a blue moving blanket

Racecar rear control arms

Small custom parts for performance.

Tell me what you're trying to build

A drawing, a model, or even just a napkin sketch: I can help you to refine your idea and make it a reality. If you're not sure about the finer particulars (like tolerances or materials selection), that's totally fine. With my experience, we can help nail the details so that the design turns out right the first time.

mechanicalsuperiority@gmail.com 970-587-3271 What to send for a quote