Case studies

A selection of projects where combining shop-floor experience with engineering made a measurable difference.

The finished stainless-steel cleanroom cover — The finished cover (background blurred for confidentiality)

CAD model with 3D scan data in Autodesk Inventor

Pharma / cleanroom

A cleanroom cover installed in 7.5 hours instead of two weeks

GMP cleanroom·on-site scan during live production·delivered under NDA

A leading pharmaceutical manufacturer needed a cover for equipment in a sterile room - components that were difficult to clean. Because our handheld Zeiss scanner is cleanable and cleanroom-compatible, we could measure the area on site during ongoing production and capture it with high precision.

We used the lead time before the planned production shutdown to develop a concept, get it approved and have it manufactured, so everything was ready when the shutdown began. The installation itself took 7.5 hours across two days - the second day spent almost entirely waiting for a glued part to cure.

Result: the client's own estimate was one and a half to two weeks of downtime during the shutdown. We did it in 7.5 hours and without disrupting production. It went so smoothly that the client asked whether we had remembered everything as we packed up.

The bike lane at Red Bull Jernhesten in Copenhagen harbour — © Esben Zøllner Olesen

The floating bike lane under construction at the quay — Photo: kindly provided by Ultra

The floating structure in Copenhagen harbour — Photo: kindly provided by Ultra

The bike lane and podium on the water — Photo: kindly provided by Ultra

Events / temporary structures

A reusable floating structure for a Red Bull event

Event production·reusable modular steel structure·reused across multiple builds

For Red Bull Jernhesten in Copenhagen (2025), event and experience agency Ultra asked us to design the supporting structure for the bike lane. The initial concept - a cantilevered structure from the dockside towards the centre of the track - became both expensive and complex because of limited anchoring options.

After some back and forth we proposed a floating solution instead, and provided the load cases and the required capacity based on the client's requirements for the lane, the podium and everything else.

We also delivered the complete documentation behind the permit the City of Copenhagen required to approve the construction. We gathered all the relevant material, reconciled the requirements and specifications against one another, and made sure the authority received a single, accurate document to base its decision on.

Result: the event was a success - and because the components were engineered as a reusable system rather than a one-off, they can now be transported to other cities and reused again and again.

As-built documentation

A clean CAD model of a 1960s production line

Reverse engineering·1960s facility, no original drawings·accurate as-built CAD

A production facility built in the early 1960s was being prepared for new machinery and a complete rebuild. Over a weekend, once the staff had left, we 3D-scanned the entire production line to document the existing layout and the actual dimensions, and handed over a cleaned model with true CAD elements for the consultants to work from - a pre-project for the full rebuild.

Because the work was scoped by someone with the mechanical experience to know what to capture, it included things the client had not thought to ask for. Among other things, we crawled into a conveyor oven to document the structure underneath, after a conversation made it clear they would need it.

Result: a reliable as-built basis for the rebuild - and the ability to capture what actually mattered. That is what we deliver: both the hardware and the knowhow.

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