Manufacturing & Factory Automation
CASE STUDY: DESIGN-BUILD MEDIUM-VOLTAGE SPLICE CABINET
Custom design • Rapid procurement • NEC compliance • Build-to-print manufacturing
The Client
Beyond New Horizons, US Air Force Prime Contractor
Beyond New Horizons (BNH), a US Air Force prime contractor, needed a custom medium-voltage electrical solution to support a fixed-schedule construction project.
The Challenge
An 18-week supply gap, an 8-week deadline
2026 industrial marketplace supply chain reality dictated that custom copper bus bars were quoted at 18–22 weeks lead time — nearly half a year.
Our Role
Redesigned for code, sourced for speed
BDRCK designed an NEC-compliant splice cabinet prototyped in Autodesk Inventor. BDRCK leveraged deep supplier connections to perform design and procurement in parallel across two suppliers to protect the schedule.
Outcome Delivered
A three-phase, 13.8kV, 300-amp splice cabinet with 100% silver-plated bus bars, delivered in 7 weeks from PO acknowledgement to site, inside a schedule most suppliers said was impossible.
CASE STUDY: SOLAR-POWERED DATA ACQUISITION SYSTEM DESIGN
Design-for-manufacturing • Drawing clarification • Integration planning • Test preparation
The Client
Multi-vendor manufacturing effort
An electro-mechanical manufacturing and integration project with complex assembly requirements across multiple vendors.
The Challenge
Documentation ambiguity at fabrication
Unclear drawings were being interpreted differently across vendors — and errors were compounding during assembly.
Our Role
Restored confidence in the design package
BDRCK clarified drawings and BOMs, supported vendor communication, and provided integration planning to get the build back on track.
Outcome Delivered
Reduced fabrication errors and a cleaner path through assembly and final integration.
