Nos Manufacturing LLC

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Nos Manufacturing LLC Engineering-led manufacturing. Concept to production for OEMs and Tier 1/2 suppliers in aerospace, automotive, and commercial. Everett, WA
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F1 replaced DRS this year with full active aero, wings that physically move between a high-grip Corner Mode and a low-dr...
09/30/2026

F1 replaced DRS this year with full active aero, wings that physically move between a high-grip Corner Mode and a low-drag Straight Mode. The rule requires that transition to happen in under 0.4 seconds, but it doesn't say how the wing has to move.

Every team assumed that meant flattening the flap. Ferrari's engineers built a mechanism that rotates the upper rear wing elements upside down instead, which opens a bigger gap and cuts more drag than a flattened flap does. Red Bull came up with a different way to do basically the same thing. Nobody broke the rule, they just read it more literally than anyone expected.

We run into smaller versions of this constantly, reading a spec closely enough to find the gap between what it says and what it assumes.

09/29/2026

Ever wonder why intake housing shape matters? 🌀

A poorly shaped housing leaves dead zones where air barely moves, plus vortices that spin energy away instead of pushing air toward the filter. Either one means part of the filter does all the work while the rest sits idle.

A better curve sweeps flow evenly across the whole filter surface instead.

Update on our aftermarket intake project for the Mazda CX-90's 3.3L turbo inline six. There's basically no aftermarket f...
09/29/2026

Update on our aftermarket intake project for the Mazda CX-90's 3.3L turbo inline six. There's basically no aftermarket for this engine right now, so we're building a custom intake for a specific customer, and we've gone from 3D scanning the stock intake to full CAD modeling and CFD simulation. Pictured: the original scanned geometry, the new intake sitting in the engine bay, and the simulation renders.

Big focus right now is avoiding dead, low airflow zones inside the rounded plenum where the filter sits, since modern engine bays don't leave much room to work with. You can see the swirl pattern we're using to spread airflow more evenly across the filter face in the streamline images, simulated at the engine's peak demand and boost condition, this is the bare housing and flow path, filter not modeled in yet. Early results using OpenFOAM through FreeCAD look promising, no major dead zones and low restriction so far.

Depending on how things look going forward, we may add flow straightening features and re-run the simulation with the actual filter in place to check what effect it has. Simulation should wrap up this week, then it's on to preparing the design for 3D printing and mounting into the vehicle.

This is the same CFD and CAD process we use for client work at NOS Manufacturing. Got a part that needs simulation or reverse engineering done right? That's what we do.

Northrop Grumman just landed a contract to build and deliver an operational satellite in 24 months, which is fast for sp...
09/25/2026

Northrop Grumman just landed a contract to build and deliver an operational satellite in 24 months, which is fast for space hardware. The trick: they're not designing anything new. The satellite bus is already in production, and the optical sensor comes from a separate company. Northrop's job is putting proven pieces together fast and getting it right.

The satellite itself is meant to get close-range, high-resolution images of other spacecraft in orbit, not just track where they are, but actually see what they look like.

We work the same way on a smaller scale. Speed usually comes from knowing which proven approach to use, not reinventing one under pressure.

09/24/2026

Why GE's next fighter engine ditches metal for ceramic in the hottest part of the engine. 🔥

Less weight, less cooling air needed, more of that air goes straight to thrust. Same heat, less compromise.

GE Aerospace just moved its next-gen fighter engine, the XA102, closer to assembly. The hot section uses ceramic matrix ...
09/24/2026

GE Aerospace just moved its next-gen fighter engine, the XA102, closer to assembly. The hot section uses ceramic matrix composite instead of metal alloy, about a third the density of a nickel superalloy, which means less cooling air diverted and more thrust for the same turbine temperature. GE's put over $1 billion into this material since the early 90s.

The other big deal: it's the first engine GE has built entirely off a digital model instead of 2D drawings. Design straight through to assembly, no translation step in between.

We're chasing the same idea on a smaller scale, keeping CAD, simulation, and manufacturing in one connected workflow instead of drawings getting redone at every handoff.

A UK firm called Alloyed just got £1 million in government funding to push a new nickel superalloy, ABD-1000AM, toward j...
09/23/2026

A UK firm called Alloyed just got £1 million in government funding to push a new nickel superalloy, ABD-1000AM, toward jet engine production. The problem they're solving: high-strength nickel superalloys crack easily when you try to print them, because the same chemistry that makes them strong at high heat also makes them fight the printing process.

They're working with ITP Aero and Cranfield University, targeting parts that need to survive temperatures pushing toward 1000°C.

We deal with the same core problem here, just with nickel alloys and Inconel instead. Strength and printability pull in opposite directions, and getting both at once is the actual hard part of metal AM.

A hypersonic vehicle needs parts that survive heat that would wreck most metals. Elmet Technologies is 3D printing heat ...
09/22/2026

A hypersonic vehicle needs parts that survive heat that would wreck most metals. Elmet Technologies is 3D printing heat exchangers out of a niobium alloy called C103, using a machine that keeps the build chamber almost completely oxygen free, because this alloy turns brittle fast if it picks up oxygen while it's printing.

They've spent 8 years working with 3D Systems' engineering team, building toward this. That's the unglamorous part of additive manufacturing nobody posts about, but it's the part that actually matters.

We work in copper, Inconel, and nickel alloys instead of niobium. Different materials, same problem: building parts that can't be made any other way, in metals that don't want to cooperate.

Big news. NOS Manufacturing is officially a sponsor of the University of Washington Formula Motorsports team. UWashingto...
08/25/2026

Big news. NOS Manufacturing is officially a sponsor of the University of Washington Formula Motorsports team. UWashington Formula Motorsports

We'll be providing 3D scanning and metrology support on their aero components, plus hands on mentorship for their aerodynamics and composites teams.

Proud to support the next generation of engineers.

Inconel 718 is the metal behind rocket motors, jet engines, and gas turbines because it holds up under extreme heat with...
08/25/2026

Inconel 718 is the metal behind rocket motors, jet engines, and gas turbines because it holds up under extreme heat without breaking down. It's also brutal and expensive to machine the traditional way.

This is an older article from the Department of Energy, first published in 2022 and updated this past May, but it still gets at a real problem. Researchers used supercomputing to predict how the material behaves during metal 3D printing, which let them design better heat treatments and, in some cases, skip extra processing steps entirely. That kind of work can mean serious energy and cost savings for manufacturers working with tough alloys like this.

This is exactly the material we work with here at NOS Manufacturing. Inconel and other nickel alloys are a core part of our metal additive manufacturing capability, especially for parts with complex geometry that would be a nightmare to machine the old way.

Got a part in a tough alloy that's been hard to produce? We'd like to hear about it.

Link to the article in the comments.

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Everett, WA
98201

Opening Hours

Monday 7am - 7pm
Tuesday 7am - 7pm
Wednesday 7am - 7pm
Thursday 7am - 7pm
Friday 7am - 7pm

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+13602179304

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