A fast-growing nuclear energy startup was racing toward a major validation milestone for its next-generation reactor. They had a promising fuel-cell concept, but they were stuck at the point where many high-tech companies get slowed down: the design wasn’t yet manufacturable, and their schedule didn’t allow room for trial-and-error on the shop floor.

They needed a partner who could take a complex, nuclear-grade design and turn it into a real, testable prototype—fast, accurate, and built to the exact tolerances their reactor demanded.

APE stepped in to help them keep their program on track.

The Problem: A Complex Tubular Chassis With Hundreds of Parts—and Not Enough Time

Tubular chassis systems offer excellent strength-to-weight performance for EV platforms, but they also introduce significant manufacturing complexity. The client faced several challenges at once:

• Over 200 custom sheet metal brackets needed precise location and fit
• Complex tube geometry required accurate bending, fit-up, and weld sequencing
• Critical shop drawings were incomplete or missing entirely
• Their engineering team was already overloaded with other high-priority vehicle work
• A fixed event deadline meant failure wasn’t an option

If they couldn’t finish the design and deliver a complete chassis in time, the vehicle reveal—and the momentum behind it—would fall apart.

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Why They Turned to APE

The company didn’t just need a fabricator—they needed a guide that could help them bridge the gap between concept and build. They chose APE because of our record of helping nuclear, aerospace, and defense innovators:

• Strengthen designs using practical Design-For-Manufacturing (DFM) principles
• Collaborate tightly with engineering teams to iterate rapidly
• Deliver mission-critical parts under demanding timelines

Speed to validation is everything for startups, and APE had the experience to move fast without compromising precision.

APE’s Plan: Turn a Complex Concept Into a Buildable, Test-Ready System

APE’s engineering team broke the problem into clear, executable steps that would get the client to testing with confidence:

1. DFM & Manufacturability Review
   We identified features that needed re-engineering, clarified ambiguous geometry, and determined where the design required segmentation or consolidation.
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2. Material & Process Optimization
   Certain sheet-metal elements were converted into precision-machined components to achieve the required tolerances and improve fit-up.
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3. Custom Tooling & Fixtures
   We designed and built assembly jigs to ensure repeatable weld quality and accurate final alignment.
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4. Continuous Engineering Collaboration
   Rapid feedback loops kept the project moving and ensured engineering intent was preserved throughout fabrication.

The Bigger Picture

This project highlights what APE brings to high-tech innovators:
clarity, speed, and precision when the stakes are too high for guesswork.

From nuclear fuel cells to aerospace structures and advanced robotics, APE helps companies accelerate development, reduce risk, and turn ambitious ideas into real-world hardware.

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Ready to Move Faster on Your Next Prototype?

When failure isn’t an option, you need a partner who can not only build your design—but help you refine it.
APE delivers design-through-fabrication support for innovators pushing the boundaries of technology.

Let’s build the future. Contact us to discuss your next project.