Engineering Services
Aerospace-Grade Innovation. Real-World Impact.
Zulu Pods offers world-class engineering services grounded in deep aerospace experience, rigorous testing, and vertically integrated development. From napkin sketch to tested flight hardware, we deliver innovative, precision-engineered solutions for defense, aerospace, and advanced systems clients.
Our fully staffed engineering & manufacturing team provide a broad suite of capabilities and experience:
Computational Fluid Dynamics (CFD) Consulting, Training & Simulation Services
Computer-Aided Manufacturing (CAM)
Digital Engineering
Engineering Design and Analysis
Failure Analysis
Finite Element Analysis (FEA)
Mechanical Testing (e.g., modal vibration, ground vibration, blade frequency, moment weight)
Heat Transfer Analysis
Instrumentation Services
Manufacturing Support
Multiphysics Simulations
Contact us to get your project started: services@zulupods.com
CORE CAPABILITIES
Mechanical & Electromechanical Systems
- Mechanical design & analysis
- Electromechanical integration
- PCB layout, embedded software, and sensor systems
- Aerospace & automotive sustainment
- Military qualification & FAA certification
Thermofluid & Structural Analysis
- CFD & FEA modeling
- Multiphysics simulations (boiling, cavitation, sprays, etc.)
- Fluid-structure interaction (FSI)
- Combustion and erosion modeling
- Reduced-order modeling
Testing & Validation
- TRL 5-6 rig and engine-level testing
- High-speed and thermal imaging
- Component validation in extreme temperatures and humidity
- Vibration and flow visualization
- Environmental and oil aging testing
Precision Manufacturing
- CNC machining (3- & 4-axis, ID/OD, surface grinding)
- Live tooling and rapid prototyping
- In-house additive manufacturing (3D printing)
- Assembly and test fixture fabrication
Modeling & Simulation Expertise
Our team leverages both high-fidelity tools (ANSYS, open-source codes, custom scripts) and reduced-order models to provide fast, reliable answers across aerospace domains. We specialize in:
- Bearing and gear thermal-fluid dynamics
- Supersonic nozzle flow
- Mist lubrication systems
- Transient heat transfer for cold-soaked components
- Aeroacoustics and porous media modeling
Facilities & Infrastructure
Zulu Pods operates out of a 5,800 sqft vertically integrated R&D facility in Western Massachusetts. We are equipped with:
- TRL 5 bearing rigs and TRL 6 engine test stands
- 400 lbf class engine stand
- Environmental test chambers (-90°F to 375°F)
- In-house CNC shop and electronics lab
- HPC infrastructure for simulation work
MEET THE TEAM
