01
MINING & AGRICULTURE
The Challenge
A Fortune 100 client needed fabrication of a massive metal assembly with a complex powder-coating requirement-something most vendors couldn’t handle due to the sheer scale.
Sintel’s Solution
Sintel leveraged its end-to-end manufacturing setup-heavy-duty lasers, press brakes, turrets, weld stations, and in-house powder coating-to deliver a seamless, competitive solution.
Long-Term Impact
To further support the client, Sintel invested over $1M+ in a large-batch powder coat system. This kept costs in check, secured long-term business, and positioned Sintel as a go-to partner for engineering and CapEx support. Years later, the relationship continues to thrive.
02
CONSTRUCTION
The Quality Bottleneck
One of the WORLD'S TOP 3 construction equipment makers challenged Sintel to improve component quality without raising cost or extending delivery timelines.
High-Tech Investment
Sintel introduced 3D automated scanners and advanced quality software—transforming traditional inspections into rapid, ultra-precise digital checks.
Results That Deliver
Quality reviews that took days now happen in hours. This tech also speeds up prototyping and legacy part replication giving clients faster speed-to-market with no compromise on quality.
03
DATA CENTER
Delay in Delivery
A data center integration partner was losing time and business due to a design not optimized for manufacturability.
Rapid Reengineering
Sintel redesigned the containment aisle structures reducing manufacturing time by over 25% while improving structural efficiency.
Repeat Business Secured
The improved turnaround helped the client win repeat orders from one of the nation’s largest cloud service providers. No extra costs, no delays-just quality delivered fast.
04
POWER ELECTRONICS
Next-Gen Ambitions
A OEM wanted to leap into next-gen Gallium Nitride (GaN) power supplies but lacked the internal capabilities to do so.
Design + Value Chain Optimization
Sintel took the OEM spec and designed bleeding edge GaN power supplies that exceeded best-in-class performance while leveraging supply chain partners to integrate many custom components.
Leading the Innovation Curve
From concept to product, Sintel helped the OEM cut through technical barriers and deliver compact, high-performance power supplies ready for large-scale deployment.
05
RENEWABLE ENERGY
High-Stakes Design
A state-of-the-art inverter project backed by the DOE and private investors needed a new housing system that was scalable, efficient, and affordable.
Total Redesign
Sintel overhauled both the enclosure and internal electrical layout-drastically reducing tooling complexity and manufacturing cost.
Commercialization Unlocked
With a 75% drop in tooling expenses and a one-third reduction in part price, the redesign made full-scale rollout feasible-accelerating clean energy adoption in mission-critical facilities.
06
DEFENSE
Design-Driven Savings
A Fortune 100 defense contractor approached Sintel to quote a major fabrication assembly for a mission-critical system. Instead of taking the design at face value, Sintel’s engineering team stepped in to optimize.
Smart Optimization, Same Functionality
Without altering the form, fit, or function, Sintel re-engineered the design—resulting in over 10% cost savings, 15% weight reduction, and a significantly simplified manufacturing process.
Automated Weld & Scalable Precision
Sintel integrated automated welding into the production line to ensure precise, repeatable output that meets strict defense standards. The use of robotics, real-time quality checks, and compliance-driven workflows enabled faster turnaround, lower variability, and higher throughput. These improvements not only delivered immediate value but positioned Sintel as a trusted partner in national defense manufacturing—capable of adapting fast while maintaining engineering integrity.
