Engineering.com and Energage are delighted to recognize companies that create positive and sustainable work environments for engineers. The Top Workplaces for Engineers award highlights organizations that prioritize employee well-being, innovation, and a supportive workplace culture.

The award is determined through employee feedback gathered via the Energage Workplace Survey, a research-backed tool assessing workplace culture. To qualify, companies must employ at least 35 engineers or have engineers make up at least 10% of their workforce. Participation is free, with no costs associated with nomination, employee surveys, or receiving the award.

This year, we recognize 35 companies for their commitment to creating exceptional workplace environments for engineering professionals across a variety of industries. Here they are, according to their size: large, midsize, and small.

As a reminder, nominations are welcome all year round! Visit topworkplaces.com/engineering-com to nominate your company for consideration on next year’s list.

Top large companies for engineers

Large companies include those with at least 500 employees worldwide. This year, we have 10 winners:

1. LJA Engineering, Inc.

Headquarters: Houston, Texas
U.S. employees: 2,531
Year founded: 1972

LJA is an employee-owned, full-service, comprehensive multi-disciplinary consulting firm. With offices across the Southeastern U.S. and Colorado, LJA offers one-source, one-stop reliability for all of its clients. It is organized around nine comprehensive sectors: Public Infrastructure, Land Development, Transportation, Water Resources, Energy Services, Rail Services, Surveying, Construction Engineering & Inspection, and Environmental & Coastal and can seamlessly build successful project teams with civil, structural, and electrical engineers, plus hydrologists, planners, landscape architects, construction managers, GIS designers, and surveyors.

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2. Infrastructure Consulting & Engineering, LLC

Headquarters: West Columbia, South Carolina
U.S. employees: 524
Year founded: 2005

Infrastructure Consulting & Engineering, LLC is a team of passionate problem solvers dedicated to delivering innovative infrastructure solutions. Founded on the principles of excellence, integrity, and collaboration, ICE has grown into a leading civil engineering firm specializing in transportation infrastructure. The team thrives in a dynamic, people-focused culture that values professional growth, teamwork, and work-life balance. They believe that great people build great projects and are committed to investing in their employees through ongoing training, leadership development, and opportunities for career advancement. From interns to executives, every individual at ICE plays a key role in shaping the future of infrastructure while upholding its core values of quality, accountability, and innovation.

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3. The Haskell Company

Headquarters: Jacksonville, Florida
U.S. employees: 1,800
Year founded: 1965

Haskell combines architecture, engineering, and construction (AEC) expertise with a corporate culture of transparency and integrity. The result is unmatched customer experience. To know Haskell is to know its spirit of innovation and assurance of certainty. To support its position as an industry leader, the company has built a distinct family of brands to best serve its clients and achieve growth and leadership in markets that provide superior opportunities. Haskell embraces each client relationship, helping them reach where they want to be, working collaboratively and strategically to deliver innovation, high quality, and sustainability performance.

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4. Sargent & Lundy

Headquarters: Chicago, Illinois
U.S. employees: 4,020
Year founded: 1891

Sargent & Lundy is one of the world’s longest-standing full-service architect engineering firms. Founded in 1891, the firm is a global leader in power, energy, and decarbonization with expertise in grid modernization, renewable energy, energy storage, nuclear power, conventional power, carbon capture, and hydrogen. Sargent & Lundy delivers comprehensive project services — from consulting, design, and implementation to construction management, commissioning, and operations/maintenance — with an emphasis on quality and safety. The firm serves public and private clients in the power, energy, gas distribution, industrial, and government sectors.

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5. Ulteig

Headquarters: Fargo, North Dakota
U.S. employees: 1,230
Year founded: 1944

As a forward-thinking leader in the engineering industry driven by purpose, Ulteig continues to focus on client success and expanding its portfolio of infrastructure and field service projects. Motivated by its corporate purpose, “Creating and solving for a sustainable future,” its professional engineering and technical services consultants cover a wide range of offerings, including design and planning, serving what it calls the Lifeline Sectors of Power, Renewables, Transportation, and Water. With 80 years in the industry, Ulteig is trusted by its clients to produce cutting-edge solutions, collaborate, and improve the design and reliability of critical infrastructure while delivering vital engineering, program, and technical solutions.

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6. EOG Resources, Inc.

Headquarters: Houston, Texas
U.S. employees: 2,971
Year founded: 1985

EOG is one of the largest exploration and production companies in the United States, with proven reserves in the United States and Trinidad. EOG’s business strategy is to maximize the rate of return on investment of capital by controlling operating costs and capital expenditures and maximizing reserve recoveries. EOG implements its strategy primarily by emphasizing the drilling of internally generated prospects in order to find and develop low-cost reserves. Maintaining the lowest possible operating cost structure, coupled with efficient and safe operations and robust environmental stewardship practices and performance, is integral in the implementation of EOG’s strategy.

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7. Stanley Consultants

Headquarters: Muscatine, Iowa
U.S. employees: 850
Year founded: 1913

Stanley Consultants has been helping clients solve essential and complex energy and infrastructure challenges for over 110 years, successfully completing more than 50,000 engagements in 120 countries and all 50 states and U.S. territories. Values-based and purpose-driven, Stanley is an employee-owned company of engineers, scientists, technologists, innovators, and client-service experts who are recognized for their commitment and passion to make a difference.

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8. Bechtel Plant Machinery, Inc. (BPMI)

Headquarters: Monroeville, Pennsylvania
U.S. employees: 1,186
Year founded: 1956

Life and culture at BPMI are deeply rooted in its “One Team, One Mission” vision. As a dedicated prime contractor for the U.S. Navy, its jobs influence and strengthen national security. It’s a serious responsibility that requires employees to be accountable for high-level quality, attention to safety, and unfailing security. Together, its employees rally around this important mission and foster a “One Team” environment where employees feel like they belong and are valued. BPMI has focused on building an environment that meets each employee where they are personally, so that they may succeed professionally. President and General Manager Barb Staniscia leads a team of managers who are dedicated to ensuring its employees have the freedom to think and speak in a psychologically safe environment — the support they need to thrive and succeed in their careers — and a deep sense of purpose and connection to their daily work.

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9. DRMP, Inc

Headquarters: Orlando, Florida
U.S. employees: 750
Year founded: 1977

DRMP’s founders, a group of engineers and surveyors, took an uncommon path in 1977 by joining together to offer their clients a full-service firm with a collaborative approach to produce superior infrastructure. The firm has never faltered on this path and continues to search for more opportunities for collaboration and growth throughout the southeastern United States. Keeping the future in mind, the company will continue its journey with the resolve and desire to create partnerships with its clients to provide tailored solutions that satisfy their needs, achieve success for its employees, and benefit the communities it serves. DRMP’s leadership is committed to creating an integrity-based firm that delivers quality projects through a partnering project approach, which provides the flexibility to work with a diverse group of clients and the communities they serve. Collectively, the leaders represent more than a hundred years of experience, which enables them to guide the firm through its forward-thinking business strategy and apply its core values to achieve client satisfaction.

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10. Orbital Engineering, Inc.

Headquarters: Pittsburgh, Pennsylvania
U.S. employees: 605
Year founded: 1969

Orbital Engineering, Inc., has a unified mission of working with business partners to create, improve, and sustain industry and infrastructure. Whether the team is in the field inspecting client assets, working with electric, gas, or water utility clients to improve infrastructure and reliability, or providing engineering support for heavy industrial clients, Orbital Engineering, Inc. is at the forefront of sustaining the country’s most critical assets and infrastructure. With over 50 years of experience in electrical and natural gas utility transmission and distribution; midstream and downstream oil, gas and chemical; mining and metals; and infrastructure industries, Orbital Engineering, Inc. has successfully supported its clients both nationally and abroad. The company takes pride in knowing that what they do matters.

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Top midsize companies for engineers

Midsize companies include those with 150 to 499 employees worldwide. This year, we have 14 winners:

1. Oddball

Headquarters: McLean, Virginia
U.S. employees: 334
Year founded: 2015

Oddball is a software consulting firm dedicated to the digital modernization of federal citizen-centric services. As a unique digital agency, Oddball supports federal clients from design to deployment of scalable software solutions that are purpose-built for the citizens they serve and the workforces they enable. Experienced teams of full-stack developers, human-centered designers, product managers, and project managers offer a proven record of delivery excellence in enterprise devops, cloud migration, user experience, continuous integration, continuous delivery, and continuous deployment.

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2. MBP

Headquarters: Vienna, Virginia
U.S. employees: 355
Year founded: 1989

MBP is passionate about providing smart solutions, which means more than just a list of services. Its diverse team of experts brings value, innovation, and efficiency to every project by advocating on its clients’ behalf. The result? Better project outcomes. Established in 1989, MBP is a leader in mitigating construction risk, offering a broad range of construction management and consulting services to optimize value within the built environment. It is a Virginia-based firm with offices in Richmond, Chesapeake, Williamsburg, Roanoke, and Fairfax, and additional offices in Florida, Georgia, Hawaii, Maryland, New York, North Carolina, Ohio, Pennsylvania, South Carolina, and Tennessee. The company works with federal, state, local, and private clients, providing cost-effective solutions in both construction management and the resolution of disputes on a wide range of transportation, utilities, building, plant, and environmental projects.

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3. Garner Health Technology

Headquarters: New York, New York
U.S. employees: 167
Year founded: 2019

Garner Health is a health tech startup that is transforming the healthcare economy by enabling patients to receive high-quality and affordable care. Garner Health has two core offerings: Garner, a benefit program that uses a new approach to data science and incentive accounts to help employees find the best doctors in their communities, and Garner DataPro, a provider recommendation platform that serves referrals based on the most accurate provider performance and directory data in the industry. Garner Health’s offerings utilize over 75% of the medical claims data in the United States to objectively examine patient outcomes based on more than 500 specialty-specific quality and efficiency measures. By analyzing millions of healthcare journeys across 82 distinct medical specialties, Garner Health sets a new industry standard in delivering reliable, actionable referrals and navigating patients to the highest-quality providers. Garner Health is a remote-first company based in NYC.

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4. BCC Engineering, LLC

Headquarters: Miami, Florida
U.S. employees: 370
Year founded: 1994

Established in Miami in 1994, BCC Engineering has always questioned the status quo, which has enabled it to come up with innovative, best-in-class solutions for some of the largest and most complex engineering projects in the Southeast U.S. and Puerto Rico. Since 2006, when principals Jose Muñoz and Ariel Millan bought the company, it has grown rapidly, adding new offices in Tampa, Orlando, Georgia, Texas, and Puerto Rico. The company is known for its complete dedication to its clients and its ability to handle a wide range of projects.

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5. LER Techforce

Headquarters: Columbus, Indiana
U.S. employees: 340
Year founded: 2020

LER TechForce is a leading provider of engineering and technical resource solutions, specializing in delivering top-notch engineering expertise across various industries. With over two decades of experience, the company has refined its ability to connect exceptional engineering talent with organizations that require innovative solutions to complex technical challenges. As a proud woman-owned business, LER TechForce is certified by the Women’s Business Enterprise National Council (WBENC), highlighting its commitment to diversity and inclusion in the workplace. Its client-focused approach is at the core of its mission, striving to deliver high-quality results by tailoring engineering services to meet the specific needs of clients, ensuring they have the right talent in place to succeed.

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6. Credo Semiconductor, Inc.

Headquarters: San Jose, California
U.S. employees: 235
Year founded: 2008

Credo was founded in 2008 by a seasoned team of analog, digital, and mixed-signal experts as a fabless semiconductor company and became publicly traded on the Nasdaq (CRDO) in 2022. Its innovations ease system bandwidth bottlenecks, and its strong SerDes IP portfolio is the foundation for its high-performance, power-efficient, and cost-effective connectivity solutions. Credo has a history of innovation and pioneering new technologies. The team believes this positions the company to deliver best-in-class products and IP solutions that address its customers’ various bandwidth, power, cost, security, reliability, and end-to-end signal integrity requirements. Its engineering-focused workforce and highly technical management team have deep industry experience and connectivity expertise. The team continues to grow, with offices in North America and Asia.

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7. FedWriters, Inc. (FWI)

Headquarters: Fairfax, Virginia
U.S. employees: 252
Year founded: 2010

FWI is a professional services firm that specializes in delivering high-quality communication, technical writing, and research services to government and commercial clients. With a team of experienced professionals who have a deep understanding of technical, legal, and regulatory requirements, FWI prides itself on its ability to work closely with clients to deliver tailored solutions that meet their specific needs. The company is committed to providing the highest quality services and has been recognized by industry organizations, including Inc. Magazine, Washington Technology, Moxie Award, and OrangeSlices AI, for its outstanding work.

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8. SCI Engineering, Inc.

Headquarters: St. Charles, Missouri
U.S. employees: 183
Year founded: 1978

Established in 1978, SCI Engineering is a multi-discipline engineering firm with six offices and almost 200 employees located in Missouri, Illinois, Texas, and Colorado. Its service lines include Geotechnical, Environmental, Natural Resources, Cultural Resources, and Construction Materials Testing and Inspection. Its staff prides themselves on their ability to provide consulting services with quality, professionalism, and responsiveness to clients during the development, design, and construction phases of projects. The company’s success is attributed to its team of highly skilled and experienced staff that includes licensed professional engineers, geologists, archaeologists, scientists, construction experts, and engineering technicians. The ability to develop innovative and cost-effective design solutions is not only a result of the diversity and experience of our staff but also the commitment between different service groups to work as a team to provide quality consulting services.

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9. Mission Design & Automation

Headquarters: Holland, Michigan
U.S. employees: 167
Year founded: 2004

Mission Design & Automation develops custom process and equipment solutions that simplify automation for North American manufacturers. The company helps conceptualize, specify, build, program, and install new automation solutions that improve safety, speed, quality, repeatability, and revenue. Manufacturers turn to the company for automation integration of varying-sized projects and with all levels of complexity. Its team has developed solutions for the aerospace, automotive, construction, consumer goods, defense, e-commerce/logistics, EV, electronics, food & beverage, furniture, medical device, and munitions industries, and it is always learning more about expanding automation applications to emerging industries.

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10. Ayres

Headquarters: Eau Claire, Wisconsin
U.S. employees: 393
Year founded: 1959

With a team of innovative problem-solvers nationwide, Ayres stands with integrity behind thousands of projects that strengthen communities and the country’s infrastructure, economy, and environment. Clients notice its project managers’ ability to translate and transform every detail into actionable, understandable, smoothly coordinated pieces of a successful project. Side by side with client partners, project managers serve as the confident, communicative navigators at the helm of each project. Their tools and expertise include civil and municipal engineering, transportation, structural design and inspection, river engineering and water resources, architecture, mechanical/electrical/plumbing engineering, landscape architecture, environmental, geospatial, planning and development, and telecommunications and SUE.

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11. Clari

Headquarters: Sunnyvale, California
U.S. employees: 499
Year founded: 2012

In 2013, Clari set out to fix an all-too-familiar business problem: unpredictable revenue. The company quickly realized that sales, marketing, and customer success teams simply didn’t have the information they needed to work together in a coordinated, cadenced fashion. Instead of acting, they were reacting. Instead of executing, they were guessing. So, Clari got to work. Today, its market-leading Revenue Platform helps go-to-market teams of every size and stripe take control of their entire sales process and revenue operation. The result? Flawless sales execution, unprecedented productivity, and revenue forecasting that really works. Simply put: nothing else comes close.

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12. Getac

Headquarters: Irvine, California
U.S. employees: 170
Year founded: 1989

Getac Technology Corporation is a global leader in rugged mobile technology and intelligent video solutions, including laptops, tablets, software, body-worn cameras, in-car video, interview rooms, and evidence management software. Getac’s solutions and services enable the vital work done by frontline workers operating in the world’s most challenging environments.

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13. McLean Contracting Company

Headquarters: Glen Burnie, Maryland
U.S. employees: 250
Year founded: 1903

McLean Contracting Company was started in 1903 by Colin McLean, making it one of the oldest companies in the Baltimore metropolitan area. It is responsible for building many of the bridges and much of the marine infrastructure in the area and owns a significant fleet of floating and land-based cranes, which are housed at its shipyard on Curtis Creek. The company’s employees take pride in being able to tackle some of the most challenging marine and infrastructure projects in the area and to provide innovative, efficient, and safe solutions for their customers.

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14. PAR Systems

Headquarters: Shoreview, Minnesota
U.S. employees: 485
Year founded: 1961

From the automated manufacturing of life-saving medical devices to the safe dismantling of Chernobyl, sending rockets into deep space, and the adaptive manufacturing of aerospace components, for over 60 years, PAR has been designing ingenious solutions that bring our customers’ innovations to life. With expertise in highly regulated and precision industries of Life Sciences, Aerospace, and Nuclear, the company designs and integrates engineered systems for the world’s most renowned visionaries.

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Top small companies for engineers

Small companies include those with at most 149 employees worldwide. This year, we have 11 winners:

1. TRX Systems

Headquarters: Greenbelt, Maryland
U.S. employees: 50
Year founded: 2004

TRX Systems develops cutting-edge positioning, navigation, and timing (PNT) solutions for the Department of Defense. The company’s military grade PNT solutions improve the safety and mission effectiveness of warfighters in environments where GPS is unavailable, inaccurate, or intentionally denied. The TRX Systems team continuously innovates, seeking to equip warfighters with the most technologically advanced and durable PNT solutions so that, even in the most adverse conditions, they always have an assured position and time.​

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2. Scrum Alliance

Headquarters: Westminster, Colorado
U.S. employees: 48
Year founded: 2001

Scrum Alliance is a global 501c(6) not-for-profit membership organization and is recognized as the leading certifying body in the scrum and agile space. As a membership association founded and funded by the agile community for the community, the team intends to advance agility and scrum practices in the world of work for individuals and teams. They nurture the agile movement by providing education, advocacy, research, community, and connection while providing individuals with substantive certifications and practical skills that positively impact their work and careers.

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3. Integer Technologies

Headquarters: Columbia, South Carolina
U.S. employees: 62
Year founded: 2021

Integer is a science and technology company dedicated to creating a safer world by transforming innovative research into fieldable technology for national security and industry customers. Its high-tech solutions help both human operators and autonomous systems make better decisions faster in uncertain environments. The company offers digital engineering capabilities across a portfolio that includes robotic and uncrewed systems, sensors and perception, power and energy systems, advanced manufacturing, and cyber-physical systems.

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4. KCL Engineering

Headquarters: West Des Moines, Iowa
U.S. employees: 71
Year founded: 2008

KCL Engineering has built a workplace where collaboration, flexibility, and self-management empower its team to thrive. The company’s entrepreneurial spirit and relentless attention to detail drive innovative solutions, making it the best consultant, problem solver, and decision-maker for its clients. Recognized as a top workplace, the team cultivates a culture where talented people love what they do — and it shows in the work they deliver.

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5. dataPARC

Headquarters: Washougal, Washington
U.S. employees: 135
Year founded: 1997

Founded in 1997, dataPARC’s team of engineers and process industry veterans continues to deliver on its promise of being the most intuitive and easy-to-use manufacturing decision support system available. The company was born from the needs of operators and engineers on the plant floor and continues to be home to process engineers, chemical engineers, industrial analytics pros, and other brilliant and dedicated individuals who share the goal of helping process manufacturers make better data-driven decisions.

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6. Hargrove Life Sciences

Headquarters: Philadelphia, Pennsylvania
U.S. employees: 90
Year founded: 2011

Hargrove Life Sciences serves the pharmaceutical, biotechnology, food and beverage, and specialty chemical industries in the U.S. and abroad. In an industry where the facility and “clean” process elements must work together, the company’s experienced teammates understand how to design and build in order to meet the rigorous GMP standards. Hargrove’s teams of engineers, architects, and project managers offer extensive experience in the planning of greenfield facilities as well as the renovation and expansion of existing process development, clinical manufacturing, and commercial operations. In addition, Hargrove has a culture and system of seamless cross-office collaboration. Its clients benefit from all the expertise of a specialized engineering firm supported by the experience and capabilities of a larger firm with a broader focus.

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7. MSB Consulting Engineers

Headquarters: Metairie, Louisiana
U.S. employees: 131
Year founded: 1978

Since 1978, M S Benbow and Associates Professional Engineering Corporation (MSB) has set out to solve the biggest engineering problems in the public and private sectors that impact the way people live, work, and play. The company produces results that are as smart as they are effective, based on the belief that there is always a better way of engineering. MSB’s success speaks to the depth of its experience and passion for delivering reliable and trusted solutions across a diverse set of complex problems. As the engineering industry has evolved, so has MSB in its ability to adapt to emerging trends and new technologies without forgetting its roots.

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8. FEA Consulting Engineers

Headquarters: Henderson, Nevada
U.S. employees: 50
Year founded: 1990

FEA Consulting Engineers, founded in 1990 by Robert Finnegan, PE, and Boyd Erickson, CPD, is a leader in multiple disciplines of engineering, including mechanical, electrical, plumbing, low voltage, AV, and lighting design. The Las Vegas-based firm is renowned for delivering award-winning engineering solutions across a broad spectrum of projects. Its approach to engineering is innovative and tailored to match the business models of its clients, ensuring that every project the team undertakes is both groundbreaking and sustainable. At FEA, innovation begins at the conceptual stage. Its dynamic atmosphere, fostered by its principals and team of associates, emphasizes innovation and a legacy of high-quality service. This commitment is evident in every project, ensuring that its designs are far from cookie-cutter and are instead innovative solutions that truly reflect the needs and expectations of its clients.

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9. PCCI Group

Headquarters: Metamora, Illinois
U.S. employees: 102
Year founded: 1982

Since 1982, PCCI Group has been providing turnkey construction and engineering solutions for underground and aerial ISPs and utilities. Based out of Metamora, Illinois, it has offices in Georgetown, Kentucky, and Bonita Springs, Florida. However, its work expands beyond its immediate service areas; the team has completed work throughout the United States, from California to Virginia, and Wisconsin to Texas.

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10. Rugged Science

Headquarters: Sparks, Maryland
U.S. employees: 37
Year founded: 2013

Rugged Science designs and manufactures high-performance computing solutions built to thrive in extreme environments. From industrial automation to military operations, its products deliver unmatched reliability, durability, and longevity where failure is not an option. Engineered to endure temperature extremes, shock, vibration, and environmental challenges like dust and moisture, its systems ensure seamless operation in the harshest conditions. With a focus on innovation, customization, and long lifecycle support, the company empowers industries to achieve their goals with confidence.

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11. Bright Machines

Headquarters: San Francisco, California
U.S. employees: 75
Year founded: 2018

Bright Machines helps the world’s most innovative technology companies automate key processes to meet the global demand for AI infrastructure. Its full-stack automation solution combines smart robotics, AI-driven software, and data to transform how the world designs and builds products. Leading with integrity and respect, the team creates a high-trust environment for performance, always prioritizing the right thing for everyone involved. As a startup, every team member is empowered to drive change and influence transformation in products, processes, people, and community.

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Is your company a Top Workplace for Engineers? Visit topworkplaces.com/engineering-com to submit a nomination!

The post Engineers have spoken: Here are the Top Workplaces for Engineers in 2025 appeared first on Engineering.com.

AutoHawk Extreme is equipped with eight performance cores running at 5.0 GHz, 12 efficiency cores at 4.0 GHz, and DDR5 RAM clocked at 6000 MHz. The system surpasses existing AutoHawk configurations for real-time execution of simulations that require up to seven high-frequency performance cores for computationally intensive tasks while still utilizing the 12 efficiency cores for ancillary, less demanding models. This makes it a suitable solution for high-fidelity, real-time vehicle dynamics and multi-body simulations, delivering raw computational power through overclocked CPUs and high-speed memory for compute-heavy, low-latency applications.

“This next-generation XiL simulation platform offers twice the performance of the previous AutoHawk 24 generation … [enabling] engineers to push the boundaries of real-time simulation with greater accuracy and efficiency,” said Guido Bairati, managing director at VI-grade.

A key differentiator of AutoHawk Extreme is its liquid cooling system, which prevents thermal throttling while maintaining system stability, performance, and low noise levels. The system is also designed with multiple PCIe slots, allowing users to customize and expand their setup with additional I/O boards. Furthermore, AutoHawk Extreme is fully compatible with PCIe expansion chassis, ensuring flexibility for future requirements.

For more information, visit vi-grade.com.

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The VARLab specializes in harnessing advanced simulation and modeling methods to tackle business challenges. Magnetic 3D’s 100-in. glasses-free 3D displays empower researchers to visualize and refine complex layouts, such as manufacturing facilities, in a fully immersive environment. By integrating real-world data, they can test configurations and simulate business processes to optimize efficiency. This smart manufacturing approach enables companies to streamline operations, reduce costs, and refine design, development, and engineering workflows before committing to physical construction. Additionally, linking the digital twin to real-world sensors provides real-time insights for ongoing improvements.

One of the core advantages of digital twins is their ability to provide dynamic 3D simulations of real-world processes. Magnetic 3D’s technology enhances this experience by adding depth perception, allowing stakeholders to step inside the simulation for a more intuitive understanding. This capability is particularly valuable in early-stage concept development, where engineers can use immersive 3D visualization to present their ideas and secure stakeholder buy-in more effectively.

Dr. Carolina Cruz-Neira, a trailblazer in virtual reality and co-inventor of the CAVE (Cave Automatic Virtual Environment), serves as co-director of the VARLab and holds the Agere Chair Professorship at UCF. Her expertise in immersive technologies will help drive innovative applications of holographic 3D displays in digital twin research, further bridging the gap between virtual simulations and real-world implementation.

“We are excited about our partnership with Magnetic 3D because their glasses-free 3D displays have incredible benefits and a lot of utility for many applications in our field,” she said in a press release. “Our research group primarily focuses on modeling and simulation in 3D environments, so we appreciate Magnetic 3D’s platform, which allows us to visualize and collaborate in 3D as a group without having to wear 3D glasses or headsets.”

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Many designers are familiar with the challenges associated with creating electrically conductive tracks across shapes with curved and complex surfaces. Let’s look at some of these issues and the drawbacks of conventional approaches in depth.

A constant compromise?

Product makers often complain that they cannot place components, such as switches or sensors, where they’d ideally like them. This is often due to constraints that limit connectivity options: a physical wire won’t fit or is too heavy, for example. Additionally, surfaces may need to be functionalized with antennas or frequency-selective components. These issues are particularly acute on complex or curved surfaces.

Some engineers will have explored traditional printed electronics, such as laser direct structuring (LDS). LDS uses nanoparticle-loaded polymers to create conductive links on curved and complex surfaces. However, the very high cost of these polymers means this technique is generally only feasible for small-scale components — think smartphone parts. Even where LDS is economically viable, you must make the entire part out of the specialized polymer, which may not be ideal for your use case.

For those looking to create conductive tracks across larger curved surfaces, the solution has generally been to shape a film containing the conductive tracks around the surface. However, anyone who’s tried this will know it’s a challenging process, with particular risks when joining conductors. It’s generally also limited to simpler shapes, laborious, and requires a highly skilled worker.

Then, you add in broader challenges. The high cost of the tooling required for traditional manufacturing techniques means flexibility is a luxury most cannot afford. Once you commit to a design, making changes is expensive, and the ability to produce multiple product variants is limited. Moreover, convoluted, multi-step logistics and production processes are typically required to build and assemble discrete parts into the final product. In addition to higher costs, all of this handling increases the risk of damage to components during production.

Put together, these issues will likely impact your products in various ways. Because of manufacturing limitations, you may struggle to create the form or function you want. You’ll lack the freedom to alter designs or create lots of product variants once you’ve tooled up. You could be experiencing high rates of damage and failure during manufacturing or simply be paying high costs due to complex logistics and handling. Where technology needs to be adaptable to competitive and perhaps hostile environments, these traditional manufacturing methods can be dangerously slow to respond.

A new way to create conductive tracks on complex and curved surfaces

Research engineers at Q5D have been developing a new set of manufacturing techniques to address these and other challenges. The techniques use a high-accuracy gantry robot to form conductive tracks as narrow as 100 microns onto large, complex, or conformal surfaces that typically form part of larger electrical devices. Crucially, the approaches can be applied to virtually any type and shape of substrate. This includes large objects, such as antennas or frequency-selective shielding in aircraft nosecones.

The techniques use materials such as copper and silver to give surfaces electrical function. This means you can connect devices via tracks or add features such as antennas or capacitive touch to your surfaces. Depending on which technique you use, metal tracks that support high currents can achieve base metal conductivity of up to 100%.

In parallel, the team behind the techniques aims to simplify manufacturing, compared to conventional methods of creating conductive tracks on curved and complex surfaces. Where other approaches require some level of off-machine processing, including difficult manual tasks, the newly developed techniques enable on-machine metallization, meaning there are fewer overall steps and less handling.

Unlocking new design opportunities

As product designers and engineers ourselves, we’re incredibly excited about the potential of these new techniques. We foresee them enabling the engineering community to add electrical function to whole new form factors and sizes that would previously have been too complex or costly to manufacture. We also see them creating opportunities to place components or functionality in new locations or produce parts that are currently unviable.

Elsewhere, the techniques bring the freedom to use the right material for each part of the product and lay the necessary conductive track onto it. This can eliminate the need to compromise on the overall material used, or the requirement to make a whole component out of expensive polymer, which may not be fit for purpose.

We’re also excited about the manufacturing flexibility these techniques promise. Because the tooling requirement has been removed, it’s as easy to create 1,000 of the same part as it is to create 1,000 different parts or variants.

For budget holders, these new approaches will bring opportunities to reduce production and assembly costs due to less handling, logistics, and human input, as well as lower risk of damage to components during production and assembly. Automating what would traditionally have been largely manual processes is also a proven way to enhance overall product quality, meaning product failure rates once in the field should also reduce.

Pushing the boundaries of engineering

To summarize, these new techniques extend the boundaries of what design engineers can create:

• Lay down a conductive track on virtually any shape and type of surface, at scale.
• Place connectivity or electrical function in places that wouldn’t have been possible before.
• Reduce or eliminate compromises you’ve traditionally had to make in your designs.
• Or simply reduce the manufacturing complexity and cost of your product.

Let’s wrap up with some use cases where these new approaches could be effective. A great example would be mobile phone antennas, where you could simplify production compared to the conventional printed electronics techniques typically used today.

In the automotive industry, these techniques are being adopted to reduce the cost and complexity of manufacturing and installing components such as vehicle interiors. They can also unlock new functionality in dashboards, such as capacitive touch surfaces, or provide greater flexibility around the placement of switches.

Because the techniques can be applied at scale and are suitable for use on composite materials used in aerospace, they offer aircraft makers new opportunities in areas such as thermal management of wing heating and the aforementioned nosecone example.

Other large-scale engineering could also benefit from using techniques on curved surfaces inside radomes for frequency-selective shielding.

The R&D team at Q5D is exploring the broader potential of these techniques in manufacturing. To learn more or see a demonstration, contact the team at q5d.com/contact.

Simon Baggott is the chief marketing officer at Q5D Technologies. He has over 20 years of experience connecting people with products across B2B and B2C technology businesses. Simon has worked in both large multinational corporations such as BOC, GE, and JDR Cable Systems and in small to medium enterprises. He holds a BEng degree in materials engineering from the University of Swansea, Wales.

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As systems have evolved from carburetors and simple exhaust systems to precision fuel injectors,  emission systems and traction and braking control systems, similar advancements have been made in electrification with new architectures, components for electric motors, battery packs and advanced power electronics. Combined, these advancements are pushing engineers to reimagine how vehicles are designed and driven for maximum efficiency, reliability and safety.

Experts from two industry-leading electronics companies — Matt McWhinney and Kirk Ulery, business development managers at Molex and Shawn Luke, technical marketing manager at DigiKey — shed light on the current state of the electrification movement and key considerations for the future of the automotive industry.

Vehicle model landscape

While the highly watched demand for electric vehicles (EVs) and hybrid vehicles continues to increase, sales of new EVs have slowed over the last several months due to many factors, including market and public policy. Industry experts cite cost and the limited charging infrastructure in the U.S. as two major reasons.

“We’ve had fits and starts on electrification in North America,” Ulery said. “If you’re going more than 100 miles at a time, you know charging infrastructure needs to be addressed.”

Hybrid vehicles, on the other hand, are outpacing EV sales. According to Edmunds data, hybrid purchases in the U.S. saw their biggest surge in 2023, increasing from more than 750,000 sales in 2022 to tipping over one million sales in 2023.

Another emerging category is the mild hybrid, which uses a battery-powered electric motor to supplement gas or diesel usage. Most mild hybrids run on a 48 V electrical system, which is a higher voltage than the electrical systems of a traditional combustion engine vehicle. The 48 V system powers components that are not reliant on the engine, enabling better operational efficiency.

Even with the fast pace of innovation in automotive design, gas-powered vehicles still rule the roadways. According to research by Edmunds, 82% of new vehicles sold today in the U.S. rely on gas. However, the electrification movement is well underway among traditional vehicles to the most advanced high-tech electric models.

Electrifying under the hood

“One constant we’re seeing is a lot more electrification — mechanical systems are becoming electrified in all vehicles for many reasons — especially to drive efficiency,” Ulery noted.

One example is stop-start technology, which turns off the engine when a vehicle stops and automatically restarts when the driver releases the brake or pushes the gas pedal. While this feature can put extra demand on some components, it aims to improve fuel efficiency and reduce greenhouse gas emissions.

Other examples of electrification under the hood are in radiator fans, power steering, HVAC systems and cooling pumps. All these systems used to be powered by belts off an internal combustion engine (ICE). Electric water pumps are replacing mechanical radiator pumps for more efficient performance, and the precise control with electrical cooling can extend the lifespan of these parts. If there is extended battery management, they also circulate coolant throughout a vehicle to regulate the temperature of the battery pack, electric motors and power electronics.

Switching to electric-powered modules such as power steering pumps makes the system no longer reliant on the engine, reducing parasitic loads and allowing for more available horsepower. Therefore, automakers can install smaller engines in some vehicles and retain the same driving performance while gaining efficiency benefits and outputting lower emissions.

“Electrification has opened the door to innovative new vehicle designs,” said Luke. “Without the need to accommodate the ‘belt driven architecture’ with a traditional internal combustion engine, auto manufacturers have more flexibility in where to distribute batteries and charging ports, the ability to increase the amount of space for passengers or cargo, and more.”

Overall, the electrification movement is replacing traditional mechanical with precision electrically controlled systems that can be more efficient. Combined with advancements in software control, modern vehicles are cleaner, more energy efficient, and offer performance and sustainability for both passenger and commercial drivers.

Vehicle battery advancement

Over the last decade, vehicle manufacturers have switched from 12 V to higher voltages, such as 24 V (especially for commercial vehicles) and now to 48 V batteries to increase power capability, reduce vehicle weight, improve acceleration and realize fuel savings.

Legislation in the U.S. and Europe has been laying the groundwork for emissions reduction in newly built vehicles. A combination of regulatory and market forces is behind the increasing shift to mild hybrid architectures, which include integrated starter generators; 48 V is not only growing in mild hybrids but also seems likely to emerge in more ICE platforms.

The shift to 48 V architecture involves more than just increasing the system voltage. It also requires a change in the electrical foundation. Feature-rich, higher-performance vehicles rely on lighter and smaller components that deliver the same electrical efficiency as a higher-density model.

“The common thing is that both 12 V and 48 V systems are moving traditional mechanical functions off a serpentine belt to a series of electric motors,” said Ulery. He shared an example of a heavy-duty pickup truck using mechanical energy for its power steering. In many vehicles, this function is becoming electrified. “The amount of energy needed for the power steering takes away from the engine’s horsepower, so by moving it to a separate electrical system, drivers can maintain more power through the drivetrain.”

The automotive industry’s move to higher voltage systems is a gradual one, given the significant impact on the design and manufacturing process. Each manufacturer’s transition is on a different timeline based on their products, technical maturity and the requirements of the customers they serve. Plus, all are held to standards and design practices related to the technologies they will be using, including:

• ISO 21780 covers requirements and tests for the electric and electronic components in road vehicles equipped with an electrical system operating at a nominal voltage of 48 V.
• The VDA Recommendation 320 is published and maintained by the ZVEI-German Electrical and Electronic Manufacturers’ Association. It covers a wide range of specifications and test requirements for electric and electronic components in motor vehicles to develop the 48 V power supply.

Following the standard to achieve smart battery management is integral to the success of 48 V architecture. With the right design process, automakers can avoid inefficient power storage, increased costs and potential safety risks to drivers.

Interconnection fundamentals to prioritize safety

With vehicles requiring more power than ever to support increasingly sophisticated electrical features, a reliable connector design for 48 V systems relies on several fundamental factors to meet vehicle performance and safety standards.

“Having electronics and the infrastructure — the interconnects to support your vehicle — is essential for safety,” said McWhinney.

Since 48 V systems operate at a higher voltage (than 12 V), connectors and electrical systems must be built with robust materials and proper insulation for safe, reliable performance. This becomes even more important if the voltage is higher than 48 V.

Connector failures can cause vehicle system malfunctions or safety hazards. To prevent disconnections, connectors should include locking mechanisms and strain relief, as well as regular inspections and maintenance checks.

“Safety and monitoring control of the electrical system is more important now than ever,” said McWhinney.

Maintaining signal quality is crucial for higher voltage applications. Poor signal integrity can precipitate malfunctions, so connectors must minimize signal loss and interference with shielded cables, as well as proper grounding and strategic placement. Addressing these considerations requires innovation and expertise, which is where advanced connector solutions come into play.

“It feels so much like table stakes, but it’s underrated how important the interconnect is in automotive design, especially for safety,” added Luke.

Keeping up with change and certification of parts

Meeting safety requirements is a top priority, but McWhinney notes that an additional challenge is the constant change in vehicle electrical system requirements, which pushes manufacturers to keep up and constantly revise connectors and other components.

Manufacturers can always refer to the US Council for Automotive Research (USCAR) to track performance requirements and carefully review and certify approved components for safe use in the automotive industry.

Components that adhere to USCAR/LV214 or similar qualifications are typically high-quality, rugged and reliable parts that can take a beating on the road without sacrificing performance. For example, Molex’s MX150 connector series offers components engineered for vehicles that face harsh environments and are durable against extreme temperatures, vibration and moisture.

“With more innovation opportunities in vehicle design, more vehicle manufacturers are embracing electrification practices,” said Luke. “Because of the hyper-fast innovation cycle, there are few standard platforms in the space. However, the increased variety offers consumers more options, and we expect the cost of vehicles will likely decrease as technology advances and production ramps up.”

Considering commercial vehicles

While much has been said about passenger cars, everything discussed in this article has been going on much longer in the commercial vehicle (CV) space. Commercial vehicles quickly transitioned from 12 V to 24 V systems to power diesel and some electrical systems, which allowed them to have smaller starters in the past. There is also a long history of electric HVAC in CVs, especially in buses, construction and agriculture vehicles and heavy-duty trucking, among others.

Commercial vehicles are typically designed to help their owner or operator make money and, therefore, must work reliably. The pressure for a CV to perform reliably is typically higher than that of passenger cars, so extra sealing and robustness are needed.

Whether designing for passenger or commercial vehicles, engineers today must consider numerous complex, power-hungry systems and features that not only meet consumer and commercial demand but are also highly efficient, durable and safe.

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Engineered to comply with rigorous regulatory standards, these solutions integrate seamlessly into a diverse range of aerospace and defense applications. These include radar systems, airborne radios, night-vision sensors, flight controls, engine controls, navigation systems, tactical weapons and military global positioning systems. Advanced materials and flexible designs address different size, weight and power requirements, ensuring these innovations are also well-suited for other high-performance applications, including medical devices, telecommunications and industrial automation.

EMI-Filtered D-Sub Pi Adapters and Connectors

Molex’s EMI-Filtered D-Sub Pi Adapters and Connectors mitigate EMI and enhance signal integrity while improving compliance with stringent standards. Featuring an optimized Pi filter design, these products provide superior noise suppression, as well as higher capacitance and inductance values for better frequency attenuation. High-quality conductive and shielding materials increase electrical performance and mechanical durability for greater resilience to vibration, shock, extreme temperatures, lightning and exposure to contaminants.

The new EMI Filter Plates help safeguard system components and prevent signal loss from electronic noise while eliminating the need for discrete filters, reducing assembly time and costs. With up to 50 lines in a compact form factor, the filter plates increase design flexibility and lower the real estate required on Printed Circuit Boards (PCBs). Snap-in variants are available for 5-to-18 GHz frequencies to further simplify installation in space-constrained applications. Customers can adjust plate size and shape to fit unique enclosures while the availability of different materials addresses a vast range of environmental concerns.

Circular EMI Filter Connectors equipped with advanced EMI filtering and line-to-line isolation to ensure reliable signal integrity and consistent power delivery are also available. Customers can choose from insulated and ground-line options in hermetically sealed and bayonet styles for greater resiliency under challenging conditions.

Fixed RF Coaxial Attenuators and RF Coaxial Terminations

Molex’s Fixed RF Coaxial Attenuators and RF Coaxial Terminations offer outstanding durability and environmental resiliency for aerospace and defense applications. In addition to those mentioned previously, these products are well-suited for military aircraft, missile defense systems, SATCOM links, ship-signal exploitation devices and electronic warfare systems. Moreover, they improve reliability of wireless infrastructure, telecommunications and automotive applications, spanning test and measurement equipment, cell-site infrastructure, network analyzers, automotive test environments and distributed antenna systems.

The new attenuators deliver precise signal power control and excellent signal integrity to ensure consistent, long-term performance. In addition, they provide heat dissipation at power levels up to 50 W and precision impedance matching, helping customers improve system efficiency, prevent equipment damage, improve test-results reliability and reduce downtime by extending component lifespans. Both product lines are engineered with solderless contacts to withstand wide temperature ranges, shock and vibration forces and exposure to harsh environments.

Where to buy

Molex’s EMI-Filtered D-Sub Pi Adapters and Connectors are available in more than 250 mechanical configurations and countless custom options, including high-density and circular connectors in a variety of shell sizes, including 9, 15, 25, 37 and 50. Molex’s EMI Filter Plates are also available in different size, shape and mounting options, which can be tailored to meet specific applications.

Supporting various power ratings and attenuation values, Molex’s Fixed RF Coaxial Attenuators ensure reliable power handling up to 100 W and work with RF connectors, including 2.92 mm, N-Type and SMA. They also are compatible with 3.50 mm, K-Type and MIL-STD-348 connectors. The RF Coaxial Terminations are available in various power ranges, power-handling capabilities and connector types, including military-grade products. They are available through Molex’s global distribution partners, with stock available immediately from Mouser Electronics and DigiKey Electronics.

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In light of the ongoing energy transition, on-road vehicles and heavy-duty equipment are increasingly dependent on lithium-ion batteries. While these batteries play a crucial role in powering the future, they are not without risks, particularly when exposed to thermal, electrical, or mechanical stresses, including manufacturing defects. Fires in lithium-ion batteries are primarily caused by thermal runaway — a process where the battery’s temperature increases in a self-accelerating cycle, ultimately leading to fires and explosions. This can occur due to factors such as overcharging or internal short circuits, where the separator melts, causing initial heat generation. As the temperature rises, the electrolyte vaporizes, releasing hazardous vapors. If no countermeasures are taken, the degrading battery enters the thermal runaway phase, resulting in catastrophic fires or explosions.

The BES series addresses these safety concerns by using Honeywell’s proprietary Li-ion Tamer electrolyte gas detection technology to identify “first vent” events. These events serve as early warning signs of potential battery malfunctions, enabling the system to issue alerts five to 20 minutes prior to a risk of fire. Such early detection is vital for ensuring both vehicle safety and the well-being of passengers and drivers alike. They also detect multiple gases released during thermal runaway, which minimizes the risk of false negatives. Its uncomplicated integration process is facilitated by a rate-of-change algorithm, eliminating the need for meticulous target gas threshold testing.

The sensors are equipped with dual operating modes and can be switched between ECO Mode and NORMAL Mode via CAN commands. In ECO Mode, power consumption is significantly reduced by 60%, as CAN communication is disabled. However, it automatically reverts to NORMAL Mode to send alarm signals to the Battery Management System (BMS) in the event of an alarm condition. In NORMAL Mode, the sensor operates at full functionality with active CAN communication.

Honeywell also released BES LITE to address needs in other non-automotive sectors and applications, such as battery energy storage systems (BESS), urban air mobility (UAM), unmanned aerial vehicles (UAV), electric two-wheelers, three-wheelers, and portable battery applications. Recent incidents of battery fires in these applications have led to significant negative publicity for respective OEMs and resulted in considerable asset damage and increased liability claims.

The BES LITE sensor is low-profile and lightweight, using Honeywell proprietary gas sensing technology to selectively detect battery electrolyte vapor. It is designed to detect gases that are typically released during the initial phase of thermal runaway as well as throughout the entire thermal runaway process. This detection capability facilitates the prompt identification of imminent dangers or risks, significantly enhancing safety measures in critical situations and allowing for proactive responses that can prevent the loss of assets and protect lives. Early detection may vary based on factors such as the nature of cell abuse and its severity, state of charge, and other variables.

The BES LITE sensor is highly resistant to siloxane poisoning and selectively responds to only battery electrolyte vapors. This enables asset protection by providing early and reliable detection of battery electrolyte vapors without false alarms, making it suitable for critical applications and environments. It also allows compliance with international regulations and guidance by providing a deterministic detection of thermal runaway events.

Honeywell
automation.honeywell.com

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By leveraging Switzerland’s neutrality, political stability, and rigorous data protection laws, WiseSat.Space is building a trusted infrastructure for secure global communications. This constellation integrates SEALSQ Corp post-quantum semiconductors, future-proofing the network against emerging quantum computing threats. These advanced chips utilize post-quantum cryptography, ensuring secure data transmission and protecting the constellation from potential adversarial quantum attacks.

Additionally, the satellites feature WiseKey’s WiseID identity management system, a platform for authenticating connected devices, and Hedera distributed ledger technology to provide a decentralized framework for maintaining data integrity and transparency across the network.

WiseSat.Space’s satellite constellation addresses the growing demand for secure and scalable infrastructure to support the exponential rise of IoT devices, projected to exceed 75 billion by 2030. Beyond connectivity, this initiative offers advanced Earth observation services for environmental monitoring, logistics optimization, and disaster response, providing real-time data and actionable insights. With tiered subscription models, governments, enterprises, and organizations can access a robust suite of services tailored to their specific needs.

Positioned as a neutral and secure alternative to satellite systems operated by corporations or national governments, WiseSat.Space claims its solution is free from geopolitical risks, data misuse, and transparency issues. By operating under Swiss jurisdiction, the system ensures compliance with the most rigorous privacy and data protection standards globally, making it suitable for critical communications. The integration of blockchain technology enhances data security, enabling decentralized, tamper-proof smart contracts and facilitating seamless transactions across industries such as shipping, logistics, and finance.

WiseSat.Space also addresses the growing need for reliable global internet access, particularly in underserved and remote regions. By bridging the digital divide, the constellation supports educational and economic growth while providing on-demand connectivity solutions for disaster recovery and emergency communications. The secure communication channels enabled by post-quantum cryptography offer security for governments, financial institutions, and enterprises requiring the highest level of data protection.

This initiative reflects Switzerland’s strategic advantage as a base for innovation. The nation’s political stability, robust regulatory environment, and commitment to neutrality provide a suitable foundation for developing cutting-edge technologies. By offering services such as private satellite networks, in-orbit servicing, and white-label solutions, WiseSat.Space extends its reach to enterprises seeking to manage their own secure and customized satellite infrastructure.

For more information, visit https://wisesat.space.

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Traditionally, simulation was used primarily as a validation tool in later stages of product development to verify that a product would meet performance and safety requirements. This approach minimized the risk of costly redesigns and failures post-manufacturing. However, placing simulation at the end of the design process limits its impact on early-stage innovation and conceptualization.

Additionally, well before today’s advanced software and computing technologies, simulation studies had limited computational power, making high-fidelity simulations time-consuming and less feasible, especially for complex systems. High costs and the need for specialized expertise restricted their use to larger organizations with significant resources. Consequently, specialized teams often conducted simulations in isolation, leading to less integration with the overall design and development process.

Modern practices integrate simulation early in the design phase, allowing for rapid prototyping and iterative improvements. Advances in computational power and software capabilities enable automated optimization that reduces iteration time and effort. Today’s software can also handle multiphysics problems, integrating tightly coupled physical phenomena for a more comprehensive analysis. Plus, as simulation tools become more user-friendly, more organizations can adopt modern simulation-driven design approaches.

What is simulation-driven design?

Simulation-driven design moves simulation from the later stages of product development cycles toward the beginning and throughout to inform design decisions. This can accelerate the design phase by allowing for rapid iteration and testing in a virtual environment before producing physical prototypes. It also enables engineers to explore innovative and unconventional designs and materials that may be too risky or expensive to test physically. Integrating simulation with design also helps engineers identify flaws and failures earlier, reducing the risk of costly recalls and redesigns after product launch.

Though this approach makes sense conceptually, implementing it can be challenging. Teams accustomed to more traditional, linear design cycles, where models and files are exchanged between design and simulation engineers, must adopt new collaborative ways of working. Much like moving from a waterfall to an agile approach, teams must transform their culture, not just their technologies or processes.

Some software providers have made simulation-driven design adoption easier by integrating CAD and CAE capabilities into one platform. They also offer cloud-based services to support asynchronous design cycles and disparate teams. Plus, such platforms are becoming more accessible so that designers and engineers of varying skills can leverage the software with less technical experience. This is often referred to as the democratization of simulation, a paradigm which opens CAE capabilities to novices and individuals in various fields. However, anyone using simulation software still needs a fundamental understanding of the problems being solved and the ability to assess the results for feasibility.

Nonetheless, with integrated CAE platforms and a simulation-driven design approach, teams can accelerate designs, improve quality and manufacturability and make physical prototyping and final testing more efficient and cost-effective.

What is the difference between a digital twin and a simulation?

The terms “simulation” and “digital twin” are sometimes used interchangeably, yet they refer to different technologies and are used for different purposes. Distinctions among the terms and technologies are up for debate and will likely continue blurring over time.

Engineers often use simulation software to mathematically model and test designs before manufacturing and to understand post-production design failures. In contrast, digital twins are virtual models that replicate the status, operation and condition of a real-world asset, such as a production-line robot or compressed air system. This requires sensors and transmitters on the physical asset to send real-time data to the software.

Though different in function, simulation and digital twins can intersect to improve products and systems.

For example, engineers may create a digital twin of a real-world machine and then test it under certain conditions. With data continuously and accurately sent to the software, engineers can simulate how changes will affect the digital twin before adjusting settings or replacing components on the real-world machine.

From a data perspective, digital twins ideally have two-way communication with the physical assets they represent, while simulation typically only receives information. Also, digital twins continuously integrate real-time data, while simulation uses static data for model analysis. However, simulations can run parallel with digital twin data feeds to predict future states, optimize maintenance schedules, identify potential issues and suggest improvements.

How is artificial intelligence impacting simulation?

Every industry is exploring how artificial intelligence (AI) can improve technology and processes. From machine learning (ML) algorithms to large language models (LLMs), such as ChatGPT, capabilities abound to reduce costs and increase efficiency and quality.

In the simulation world, AI could be a gamechanger. It can automate tasks and streamline workflows so designers and engineers can focus on higher-value work that only humans can do. It also opens doors for non-experts to create designs and approximations with less technical skills.

For instance, AI algorithms can optimize computational processes and reduce run times. Simulation techniques such as reduced-order modeling (ROM) use AI to simplify complex models and speed up solving without compromising accuracy. ML algorithms can also improve validation by continuously learning from simulation results to detect errors and anomalies.

Some software providers are exploring a bottom-up approach to develop physics-based AI models that bypass the mathematical equations underpinning current solvers. Such software could analyze a CAD model’s behavior under loading conditions in a fraction of the time compared to traditional solvers. Simulation studies could be 100 times faster due to the AI algorithms alone and another 10 times faster using GPUs.

While a bottom-up approach attempts to create a general-purpose simulation AI trained on physics, top-down AI targets specific problems based on narrow training data. A top-down approach can be applied to any simulation problem, but as soon as the problem is tweaked, the simulation breaks down, and the AI must be retrained. Though much more limited than bottom-up simulation, it is also easier to develop, which is why many simulation companies have already begun commercializing it.

Of course, there are caveats. AI’s effectiveness relies on data quality and availability. Poor data can lead to inaccurate models and predictions. Also, AI often requires significant computing resources, especially for training complex models, which can seem more like a problem shift than a solution. Regardless, many engineers look forward to incorporating more AI capabilities into simulation software to solve bigger problems faster and more accurately.

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For example, engineers may need to analyze the stress and deformation of an aircraft wing under aerodynamic loads or compute thermal deformation in engine components. FEA is also used when the fluid and structural response need to be analyzed simultaneously, such as interactions between blood flow and artery walls or dam deformations due to water pressure.

Computational fluid dynamics (CFD) simulation is used when the primary focus is on analyzing fluid flow, heat transfer and related phenomena. This includes the behavior of fluids in motion, such as airflow over a car body or water flow around ship hulls. CFD is also used when analyzing thermal phenomena involving fluids, such as convection cooling in electronic devices and combustion processes in engines.

In cases where fluid flow affects structural integrity and vice versa, an integrated approach using both FEA and CFD might be necessary. For example, aerospace engineers may use CFD to determine the pressure distribution over an aircraft wing and then use FEA to analyze the wing’s structural response to the pressure. Similarly, civil engineers may use CFD to simulate water flow around a pier and compute the hydrodynamic forces, and then use FEA to assess the pier’s structural integrity in response to such forces.

The general rule of thumb is to use CFD when the problem primarily involves fluid behavior, heat transfer within fluids or the interaction between multiple fluid phases, and to use FEA when the focus is on the structural responses to external forces, including those induced by fluid flows, thermal stress and FSIs.

Alternatively, engineers can use multiphysics simulation to solve FSI problems simultaneously.

Multiphysics software includes coupled solvers that can handle the simultaneous and dynamic interaction between fluids and solids and solve the governing equations for both in a synchronized manner. It can also handle moving and deforming meshes to model how fluid changes shape due to structural deformation.

Multiphysics simulation uses either a monolithic or partitioned approach to ensure convergence of the coupled FSI problems. The monolithic approach simultaneously solves the fluid and structural equations in a single system of equations, which can be more stable but computationally intensive. With the partitioned approach, the software solves the fluid and structural equations separately and iteratively exchanges boundary conditions until convergence is achieved.

Coupling methods for the partitioned approach are considered either one-way or two-way data exchanges depending on how the fluid flow and structural deformation affect each other. In a one-way data exchange, the simulation is performed in a particular order, and the results from the first analysis are inputs for the second analysis, which doesn’t affect the first. This is similar to running a CFD simulation to calculate aerodynamic pressure on an aircraft wing and then running an FEA to analyze the wing’s structural response. In a two-way data exchange, the fluid and structure affect each other dynamically, so the simulation runs iteratively and exchanges data back and forth to more accurately represent the coupled behavior.

Overall, the choice between using separate FEA and CFD software, multiphysics software and the simulation approaches and methods depends on the nature of the problem being studied, the required accuracy and the available time and computational resources.

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