Our Engineering Projects

TURNKEY TESTING, AUTOMATION, AND BESPOKE SYSTEMS DELIVERED FOR GLOBAL MANUFACTURERS

Our Bespoke Engineering Projects

At Curtis Assemble & Test (CAT), we design and deliver turnkey automated testing and assembly systems trusted by leading manufacturers worldwide. Each project combines our mechanical , electrical , and sof tware expertise with decades of engineering excellence to create high- quality, bespoke solutions — from initial concept to commissioning and af ter- sales support.

Our work spans industries including automotive, aerospace, defence, energy, and precision engineering. Explore some of our recent projects below to see how CAT provides hydraulic and pneumatic testing, vision inspection systems, flow measurement rigs, automation solutions, and component cleaning systems tailored to unique customer requirements.

Engine Timing Gauge

Automatic Gauging Unit for Perkins/Caterpillar Engines

This bespoke system measures multiple aspects of 400-series diesel engines, including head gasket thickness and fuel injection pump shim thickness.

High-Precision Technology: Features a Micro Epsilon 2060 measurement sensor mounted on a 6-axis robotic arm for accurate, automated measurement.
Flexible Production: Handles any engine variant in any order — no tooling changes required.
Data Integration: Results are stored in a local SQL server database and linked to the factory MES system for real-time traceability.

The system is designed for accuracy, efficiency, and reliability, helping manufacturers maintain strict quality standards

Engine Timing Gauge Automatic Gauging Unit for Perkins/Caterpillar Engines

2 Piece Wiper Seal in Rotor Assembly Machine

Delphi Diesel Systems (Now Phinia Delphi)

This retro-fitted automated assembly solution was installed on an existing production line to assemble two precision components into eight small sub-assemblies within a 14-second cycle time.

Bespoke Engineering: Developed to integrate seamlessly into the customer’s live production line.
Advanced Manufacturing: Used complex material forming and 3D printing processes to overcome production challenges.

CAT followed a project plan and delivered on time. Clear and concise technical support was given when required Jim Holder, Engineer, Delphi Diesel Systems

2 Piece Wiper Seal in Rotor Assembly Machine Delphi Diesel Systems (Now Phinia Delphi)

Looking for a trusted partner for your next project?

Talk to our experts today and discover how CAT can deliver the bespoke automated testing and assembly solutionyour business needs.

Request a Consultation

Laser Measuring Equipment

Analysis of a Round For A Defence Company

This fully automated system measures the diameter and straightness of large defence components with micron-level precision.

Manual Loading, Automated Analysis: Ensures operator safety while maintaining accuracy.
High Data Output: Generates over 1,000,000 data points per component for comprehensive evaluation and full quality assurance.
Efficient Cycle Time: Typical cycle is 2–5 minutes, plus loading and unloading, making it ideal for production environments.
Optional Vision Integration: Adds visual inspection of screw patterns and correct assembly verification.

By combining automation, precision measurement, and traceable data logging, this system meets the demanding standards of defence manufacturing while ensuring speed, safety, and repeatable accuracy.

Laser Measuring Equipment Analysis of a Round For A Defence Company

Diesel Injector NCV Assembly Machine

Selective Assembly Machine for Phinia Delphi

This advanced machine assembles 2mm NCV guide and pin-matched pairs, then performs a full sequence of assembly, measurement, and testing to ensure precision and reliability.

Automated Handling: A robotic system moves components through each stage — from the input pallet, across all intermediate stations, and back to the output pallet.
Comprehensive Testing: Includes lift measurement, two seat pressure tests, and one flow test, ensuring accuracy at every stage.
Software Flexibility: Stores, changes, and controls multiple variants of test plans. Functions such as assembly, lift measurement, or individual hydraulic tests can be turned off or adapted within the software.
Hydraulic Leak Testing: The system hydraulically pressurises each component to check the interface between a retained ball and the machined seat. Leakage is measured as pressure decay over time — with configurable software settings (e.g. a 5-second stabilisation period followed by a 5-second decay measurement).

Diesel Injector NCV Assembly Machine Selective Assembly Machine for Phinia Delphi

Why Choose CAT?

Turnkey Solutions – From concept to commissioning, we deliver complete in-house engineering and support.
Proven Industry Trust – Partnered with leading automotive, aerospace, defence, and energy manufacturers.
Problem-Solving Expertise – We often rescue projects that fail with cheaper, off-the-shelf alternatives.

Flexible Control Systems – Bespoke software and automation tailored to manual or fully automated testing.
Precision & Reliability – Every project is designed to meet exacting standards for accuracy and repeatability
50+ Years of Heritage – Decades of expertise combined with cutting-edge innovation.

Torque Controlled Screwdriver Unit

Assembly Aid for a Defence Company

This semi-automatic assembly aid was developed to support operators during the installation of critical components, ensuring accuracy, repeatability, and compliance with defence standards.

Operator Support: A manually loaded fixture assists the operator in positioning and securing the correct number of screws.
Precision Control: Each screw is tightened to its specified torque and angular distance, guaranteeing consistent assembly quality.
Integrated Monitoring: A torque screwdriver system is built into the existing fixture and monitored via a bespoke interface.
Full Traceability: The interface records the number of rotations, torque applied, and screw presentation to ensure every fastening meets specification.

This solution provides a reliable, efficient method of maintaining assembly integrity while reducing the risk of operator error

Torque Controlled Screwdriver Unit Assembly Aid for a Defence Company

Flow and Pressure Testing

Crane Building Services & Utilities

This bespoke test rig was designed to support new product development of dynamic variable flow control valves.

Versatile Testing: Handles valve sizes from ½ inch to 4 inches, supporting a wide range of product applications.
High Capacity: Delivers flow rates up to 30 litres per second at pressures of up to 6 bar.
Data-Driven Performance: Features fully integrated data logging and test reporting for traceable quality assurance.
Flexible Operation: Provides total software flexibility, allowing variability in test parameters with both manual and automatic control, giving engineers maximum adaptability during development.

Solving our design problems with innovative solutions, CAT lead us in the right direction to get the best results possible Richard Challis, Senior Engineer, Crane Building Services & Utilities

Flow and Pressure Testing Crane Building Services & Utilities

Looking for a trusted partner for your next project?

Talk to our experts today and discover how CAT can deliver the bespoke automated testing and assembly solutionyour business needs.

Request a Consultation