Prototype Build

GS Engineering complements the concept design, analysis, and vehicle testing with a competent prototype build capability. GS Engineering has high bay space with overhead cranes to remove the engine, the dump body, or to raise the vehicle to install a track over the wheels. GS Engineering employs heavy vehicle mechanics who are accustomed to the level of experience that is demanded by our customers. The typical project is one that first starts with a CAD model, is optimized through ANSYS FEA and Altair, and is fabricated and installed on the vehicle. GS Engineering has an extensive network of manufacturing suppliers from aluminum casting to laser cutting, bending, welding, and even resin-based composite material supply.

In many cases, our customers want their components, subsystems and vehicles field tested in a quiet, secure manner to collect relevant data to develop and refine their product.  GS Engineering provides a wide array of sensor technologies to measure vehicle/component inputs over various terrain and obstacles provided on our customizable, 423 acre off-road test course.

Representative Prototyping Projects include:

Truck Systems & Components – GS Engineering designs and fabricates components for rapid response programs for military, commercial and off-highway vehicles .

FMTV Bandtrack over Wheels - To aid mobility in soft soil, GS Engineering designed, fabricated, installed and tested a rubber bandtrack over the rear wheels of an FMTV.

High Output Exportable Power System for Military Vehicles – Addressing the need for increased vehicle and exportable power, GS Engineering developed and integrated a high output power system on a medium tactical vehicle. A belt-driven permanent magnet generator provides 14/28V @ 100/200A of vehicle power at engine idle (700 RPM), and 56V @ 600A of exportable power at high engine idle (1350 RPM). A DC-AC inverter provides up to 28kW of continuous exportable AC power (120/208 3 phase 4-Wire with ground), with selectable frequencies of 50, 60 and 400 Hz.

Lightweight Brake Drum – In conjunction with Century, Inc, GS Engineering has developed a lightweight aluminum metal matrix composite (MMC) brake drum for the heavy vehicle market.

Lightweight Mine Roller – Addressing the critical need of land mine and IED neutralization, GS Engineering is developing a lightweight mine roller that will mount to the light vehicles such as the HMMWV. GS Engineering’s dynamic amplificiation technology is the key to enabling the lightweight design.

Lightweight Roadwheels – GS Engineering has over 20 years of experience in military track and suspension, including road wheels. GS Engineering’s roadwheels are lightweight and durable. GS Engineering continues to pursue technologies that will bring a lower cost, yet longer lasting road wheel to the tracked vehicle market.


Contact us today to learn more about our protoype building services.