Results from critical programmes
Each case study shows the challenge, our approach and the measurable outcome. Delivered by founders prior to founding ATLAS.
CASE STUDY 01
Rapid engineering recovery for a critical defence programme
15 working days
To resolve a critical design issue and keep the international assembly schedule on track.
The challenge
A critical design issue in a hazardous packaging solution threatened the schedule and international assembly readiness of a defence experiment. It needed a robust solution in an exceptionally compressed timeframe.
Our approach
Options were evaluated against performance, safety, manufacturability and programme needs. The preferred solution was substantiated and taken through design assurance and approval, engaging with the regulatory body throughout.
The outcome
The issue was resolved within 15 working days, keeping the international assembly schedule and supporting logistics readiness, and showing the value of competent engineering judgement combined with stakeholder management and decisive leadership.
CASE STUDY 02
Cutting manufacturing lead time through advanced manufacturing
6–9 months → 8–12 weeks
To manufacture and assemble a specialist diagnostic assembly for trials use
The challenge
A specialist diagnostic assembly needed a major reduction in manufacturing lead time while maintaining the performance and robustness demanded in a highly volatile environment. Reliance on traditional manufacturing methods meant long lead times, impacting programme critical path.
Our approach
The diagnostic was redesigned around modular sub-assemblies, advanced optical design and additive manufacturing. With bespoke printed components, advanced optical characterisation and dedicated tooling, development cycles were undertaken to ensure the design met the requirements.
The outcome
Manufacturing and assembly time fell from around 6–9 months to 8–12 weeks, showing how advanced manufacturing ensure repeatability, meet performance requirements and reduce production timelines.
CASE STUDY 03
From engineering design to verified trial evidence
End to End
Engineering support across the trials lifecycle, from requirements definition to trial readiness.
The challenge
A defence programme needed a series of complex experimental assemblies to generate the trial evidence behind major programme decisions. Stringent requirements for performance, safety, configuration control and assurance had to be met, with close coordination across multidisciplinary UK teams and international partners.
Our approach
Mechanical engineering, physics, materials, diagnostics and manufacturing teams were brought together to develop the design solution. Configuration control and traceability from requirements to verification evidence were maintained using Product Lifecycle Management (PLM) tools. Emerging challenges were resolved quickly within appropriate safety and governance controls.
The outcome
Multiple complex trial assemblies were delivered successfully, de-risking the programme's performance requirements in the early stages of product development.
CASE STUDY 04
Delivering complex experimental assemblies under facility constraints
Zero delay
Programme recovery after a critical lifting asset failed midway through the experimental assembly.
The challenge
A complex experimental assembly had to be delivered in an ageing facility where plant and limited handling capability put schedule and build quality at risk. Midway through operations, a critical lifting asset failed.
Our approach
The assembly approach was redesigned around the facility's limitations, with alternative handling methods, bespoke tooling and revised build sequences to protect hazardous components, adopting an ALARP methodology. Changes were validated through inert run-throughs supported by relevant subject matter experts (SMEs) prior to approval.
The outcome
A pragmatic solution was adopted and the overall project was completed to schedule.
CASE STUDY 05
Independent verification strategy
Full lifecycle
A verification and qualification strategy giving senior stakeholders a defensible basis for major decisions.
The challenge
A significant defence programme needed a comprehensive verification and qualification strategy to demonstrate that a complex system would meet its performance, safety and lifecycle requirements. The work spanned multiple disciplines, organisations and international stakeholders.
Our approach
Design Authority thinking and independent assurance were used to define the right mix of engineering judgement, modelling, simulation, analysis, trials and testing across the lifecycle. Verification planning, qualification strategy and life assessment were brought together, with evidence structured to support performance and safety requirements as well as facility safety cases.
The outcome
The resulting framework gives multi-agency and regulatory stakeholders a coherent technical basis for design decisions and confidence in system performance and safety requirement compliance.
CASE STUDY 06
Tooling and process innovation for hazardous material assembly
New standard → Reduced risk
Validated tooling and processes adopted as the standard approach for subsequent assemblies.
The challenge
An experimental trial assembly needed new tooling and processes to handle hazardous materials. Existing methodology was slow, risk-prone and lacked the substantiation evidence needed for approval in a regulated environment.
Our approach
Bespoke fixtures and new assembly processes were designed and validated through structured verification using mock components. Hazard analysis and process optimisation were embedded early to meet ALARP principles, working closely with operations and safety specialists.
The outcome
The customer received a complete, validated tooling package that reduced operational risk, improved repeatability and shortened assembly schedule.