"Czero is one of the best companies I have worked with for analysis and simulation; including dynamic modeling, CFD and FEA. Their deep expertise and comprehensive quality system ensure accurate results. Czero's project management is excellent, providing clean concise information on progress, schedule and budget. Czero is a go-to source for projects ranging from analysis and simulation to prototype product development and testing. They deliver strong solutions to the challenges faced by Offshore and Subsea markets."
Reverse Engineering Expertise
As an engineering service company with a wide array of project types, Czero routinely draws upon our abilities to reverse engineer hydraulic, pneumatic, electrical, control, and mechanical systems/sub-systems or combinations thereof. Our expertise is generally needed for a couple different reasons:
- Our customer, like the Defense Logistics Agency (DLA), requests that we provide reverse engineering services for obsolete parts.
- We extrapolate or modify existing products to make unique one-off prototypes or make prototypes for unique applications.

Typically, the reverse engineering (RE) process will start by understanding if all other avenues to obtain technical data has been exhausted, understanding the benefit vs. cost of doing so, and ensuring that RE is not prohibited because of intellectual property infringements.
With minimal starting information, Czero can create full manufacturing prints for components which cannot be procured by other means. We have extensive experience with tools and supply partners that allow us to create a full high-quality technical data package (TDP), Qualification Test Procedures (QTPs), required prototypes, and other materials that allows for complete manufacturing of replacement parts when starting with as little as a hardware example.
Czero steps in when a TDP is not available, or there has been a disruption in the supply chain, or information has been lost, or suppliers discern differences between allegedly same parts. When manufacturers do not provide adequate support or replacement parts, our reverse engineering enables repairs or remanufacturing and continued servicing of products. Czero helps ensure usability and keeps equipment operational when documentation or technical support is unavailable. We assist with reviving old systems; for products "end-of-life'd" or no longer supported by their original manufacturer, reverse engineering is necessary to maintain, update, or reproduce them.

Some common project related tasks where reverse engineering is employed at Czero are:
- A customer engages Czero to understand why a system is not operating correctly or is failing prematurely. Depending on the specific issue and the available customer information, this understanding is often achieved by reverse engineering to system to understand physical and operational characteristics that can be used in an analytical model such as a dynamic analysis, FEA, CFD, or a magnetic analysis to name a few.
- Commercial Off The Shelf (COTS) systems (motors, heat exchangers, valves, etc.) are often utilized in customer applications. In instances where an overall analytical model or 3D representation of the complete system is a required deliverable, these COTS items will need to be reverse engineered to adequately capture geometric characteristics or function of the COTS.
- To leverage engineering that has already been performed for COTS assemblies, Czero will often try to use these COTS assemblies/parts where appropriate in customer applications for which these items where not originally intended. To ensure proper function, these items need to be modified. These modifications may range from simple geometric alterations to ensure proper fit into the unique application or more complex modifications if the customer application requires the COTS system to function outside of its originally intended operating range.
- Czero also receives many projects where a customer would like to show that their specific concept will outperform existing technology. In these instances, Czero will create dynamic models or perform simulations on both systems to evaluate and compare the function of each system. After this analysis, both systems are typically tested to ensure the validity of the analytical comparison.
- Many projects that Czero executes also require integration of existing controls systems with new components or systems. In these cases, reverse engineering of these existing controllers and associated safety systems must be performed.
Aerospace Components for DLA
Czero provides reverse engineering services to the U.S. Department of Defense (DoD) through the Defense Logistics Agency (DLA). We perform reverse engineering of aircraft parts and help with making parts that are no longer available and keep the country's established fleet of planes in the air. Czero has created TDP for parts on the following aircraft.







Example RE Work
Since our company inception, reverse engineering has been a portion of many of the projects Czero executes. A partial list of some of the items Czero has reverse engineered as a part of larger projects is shown below:
Air compressors | Pilot stage hydraulic valves | Planetary gear sets |
Automotive cams | Pressure regulators | Braking systems |
Automotive pistons | Subsea hydraulic actuators | Test fixtures |
Various seals/gaskets | Liquid fuel injectors | Natural gas metering equipment |
Intake/exhaust manifolds | Gaseous fuel injectors | Engine blocks |
Main stage hydraulic valves | Pressure vessels | Medical equipment |
Material evaluations | Vehicle frames | Power transmission parts |
Pneumatic valves | Control system function | Oil & Gas equipment |
Reverse Engineering Services
Czero's reverse engineering services involve the detailed analysis and deconstruction of complex systems to understand their design, function, and underlying principles. This process is often used to analyze intricate machinery or components where original design specifications are unavailable or need to be improved. Our engineers meticulously dissect each part of the system, leveraging modern tools like 3D scanning, CAD software, and computational modeling to recreate accurate models. In such high-level engineering, reverse engineering not only aids in replication but also in optimizing performance, identifying potential design flaws, and innovating upon existing technologies. The process requires deep expertise and precision, especially when working with cutting-edge or highly specialized systems.
Czero Engineering Overview
Czero Capabilities
Software & Tools
Czero has spent years developing/vetting external vendors that can conform to Czero’s rigorous requirements and quality expectations. These companies are continuously graded on quality and their ability to deliver within the originally quoted budget and timeline. We have vetted resources that can provide numerous material identification services that not only give insight to the material being used but also how the materials have been processed (forged, cast, machined), and the heat treat performed (hardness, grain size, phase, etc.). These capabilities include but are not limited to:
- Optical Emission Spectroscopy (OES) will be used to determine chemical composition of metallic samples. In many instances, if the sample material is too small or the geometry of the material does not lend itself to testing, it may be melted or deformed into a shape that allows for this test to occur.
- X-ray fluorescence (XRF) is the preferred non-destructive test that can be used to determine the elemental composition of materials. This type of testing will be used to understand what coatings or surface treatments have been used on the components that comprise the Valve, Flow Control assembly.
- Cross-sectioning and Scanning Electron Microscopy with Energy Dispersive x ray Spectroscopy (SEM-EDS) will be employed when necessary to identify microstructure, heat treatment, coating chemistry, uncoated surface condition, coating thickness on components. Typically, a portion of the component of interest will be cross-sectioned, mounted, ground and prepared for the SEM.
- Fourier Transform Infrared Spectroscopy (FTIR) will be the preferred method used to determine the plastics, adhesives and conformal coatings used in the Valve, Flow Control assembly.
- Microphotographic and/or stereo optical microscopy to identify surface condition/treatments, coatings, and any markings from manufacture.
- Laser-Induced Breakdown spectroscopy (LIBS).
- Inductively Coupled Plasma (ICP)/MS.
- Micro-Raman spectroscopy and Differential Scanning Calorimetry (DSC) with Thermogravimetric Analysis (TGA) to determine polymeric content if sample size is too small.
- Nuclear Magnetic Resonance (NMR) testing, for some polymer materials that need finer grading.
- Hardness tests and Pull tests may also be required to determine level of heat treat or work hardening of the material.
For metrology, we have standard hand metrology tools, (calipers, bore micrometers, micrometers, gage sets, drop gages, etc.) as well as a Faro Arm.
We have also outsourced Coordinate Measuring Machine (CMM) work when we are not capable as well as precise 3D digitization of components. On occasion, we have outsourced Computed Tomography (CT), the outputs of these scans can identify and dimensionally inspect any internal features that are not visually apparent (for cases when the destruction of components to be measured is not allowed).
We also take advantage of vetted external test facilities when any required testing exceeds the capabilities of out in house equipment. External testing Czero has outsourced in the past include but are not limited to: shock and vibration, strength testing, corrosion, and a variety of other environmental related testing.
Process
Our reverse engineering process is shown below:

Supply Chain Stability
Our services play a critical role in mitigating supply chain disruptions, particularly when original parts or components become unavailable due to shortages or discontinuation. By deconstructing existing parts and analyzing their design and materials, Czero engineers can recreate or improve upon these components without relying on the original manufacturers. This allows companies to maintain production continuity, sourcing alternatives or fabricating parts in-house. In the context of complex mechanical systems, reverse engineering ensures that even highly specialized components can be replicated or optimized, reducing dependency on volatile supply chains. It provides a strategic advantage in maintaining operational efficiency during unforeseen supply interruptions.


"Nexceris has been working with Czero since 2018 to develop and demonstrate a 50-kW scale hybrid power system for a government customer (ARPA-E). Czero led system design and controls development, and currently is leading system construction and testing work on the project. Czero engineers are extremely talented, innovative, detail oriented and responsive. I have thoroughly enjoyed our collaboration and provide my highest recommendation."
"PDC Machines- a compression and refueling technology provider to the world’s emerging hydrogen economy has been working with Czero for over 6 years on a combination of greenfield new technology and incremental technology improvements to our product. They have been able to take our napkin sketch frameworks and work with our team to deliver minimum viable product to complete solutions which are efficient, marketable and in many cases patentable. Their clear and simple approach to partnership- working as part of one team PDC staff is why I believe in the growing foundation we started 6 years ago."

"We chose Czero since they have a stellar reputation for innovation and expertise in the automotive industry. They also have a proven track record and prior history with the original inventor [of Onboard Dynamics natural gas refueling technology]—who is on our team—that has already resulted in huge successes in meeting critical milestones and performing to expectations."

"I have a >$1M US Department of Energy research effort for which I was understaffed and lacking specific subject area expertise. Czero was able to engage last minute to displace a well-known automotive engineering company at a fraction of the price. Over a year into the project, Czero has continued to be responsive and trustworthy; their engineering performance has contributed significantly to an increase in project funding from the sponsor. As the project principal investigator, selecting Czero as an engineering services company has been one of the best decisions I have made."

"Czero’s work with us to fully understand the requirements of the end product for the new reactor engine system has been instrumental in developing a completely new, innovative system. From these requirements, they were able to quickly come up with multiple concepts for vetting against the tough project objectives, which include not only technical feasibility but also aggressive cost targets. The in-depth simulation and analysis of the various concepts that Czero did ahead of time has built tremendous confidence we are going down the right path."

"Czero’s ability to work with our engineers in developing innovative, ground-breaking technology has been a great benefit to the SuperTurbo development. We have placed a lot of trust in Czero’s ability to deliver and have not been disappointed. They are a top-shelf organization."

“My initial request to Czero was to develop software and the associated controller needed for a very important competitive assessment of our product. Due to the nature of the project, I needed the work to be accomplished and in my customers hands within 2 months, which was a very aggressive necessary timeline for this level of work. Not only did Czero get the software and ECU requirements done to spec, but the system was delivered to my customer ahead of time to support the testing. The expertise, timeliness, and quality of the Czero solution was outstanding!”

"We’ve had an absolutely fantastic, positive experience with Czero and I wholeheartedly endorse them. They are more than a typical ‘throw it over the fence’ engineering consulting firm, as Czero not only develops a strong understanding on the background of the project, but they also think along the way and offer suggestions and ideas beyond the scope of the simple engineering contract deliverables. And, they deliver, too. They are really solid, outstanding people."

"The engineers on the Czero team were proactive problem-solvers from our first introduction. They quickly applied the full breadth and depth of their engineering team’s impressive intellect to determine the most efficient and cost effective system to maximize the energy-harvesting capabilities of Brown’s concept.
They were remarkably objective in their trade studies to find the best solution, favoring a simpler mechanical solution over their greatest strength: advanced hydraulics. They walked us through potential failure modes of each system, and educated the team about the pitfalls of component scalability. In addition to their technical solutions, Czero did an excellent job conveying their thought process and analysis to the Brown team with clear graphs, diagrams and presentations, which streamlined decision-making.
Czero added tremendous value to the Brown project and was a pleasure to work with. We look forward to putting our heads together on future projects."

"Czero has been an invaluable and integral part of our program. From component and subsystem design to detailed system performance analysis, Czero’s integrated engineering approach has allowed us to develop elements quickly to meet the very ambitious schedule challenges imposed by our U.S Department of Defense contract."

"Czero has been a valuable strategic partner in helping FACTOR[e] startups advance technologies quickly while staying lean during their crucial first two years. We know Czero’s agility, creativity and process. We trust their team. We’ve seen their technology insights and the business value of what they deliver."

"As we move from R&D to commercialization, Czero is providing top-notch engineering support to our team, transforming our ideas and concepts from prototype designs to viable commercial products. Czero really digs into the requirements before starting the design process, enabling us to easily collaborate on design options that optimize our product designs to meet market demand and ensure customer satisfaction. Without hesitation, we recommend Czero to anyone wanting to accelerate R&D and product development."

"Czero understood our test objectives very quickly and communicated systematically to define the test procedure, scale model details, and test fixture that fulfilled all test requirements quickly and safely. They creatively utilized off-the-shelf items in the scale model to keep its cost low and provided a clear, concise report—including useful insight—within a week of test completion. Helix is very pleased with the service provided by Czero."

"With extensive experience in engine systems design, Czero played a vital
role in helping Logimesh expedite concept-to-prototype development and
testing of our award-winning Logimote engine health monitoring platform."

"Czero was the right partner to help us design our custom grist bin and bag intake station. They found the perfect balance between a properly engineered solution, a cost effective solution, and an aesthetic solution."

"The true sign of individual or organizational dynamism is the willingness to take risks. It signals real confidence in capabilities and know-how, the flexibility and creativity to explore and test new solutions, and guts to do what it takes to deliver under real economic and technical uncertainty. Czero epitomizes those characteristics and combines them with old-fashioned integrity and reliability. Needless to say, their engineering and technical capabilities are superb. As a young company commercializing real black-box technology, we've entrusted Czero with taking responsibility for critical design and engineering tasks for which there are no precedents, i.e. it has never been done before. They have delivered, under demanding time and resource constraints, and set a very high bar. Culturally and otherwise, they are an ideal partner for young startups who need deep-dive, blank-slate engineering solutions. I would recommend them to anyone."

"Czero was an insightful and very technically proficient group that were instrumental in helping us develop our technology. They were very quick studies to understand the fundamental challenges we faced and design/build solutions around them. Top qualities: Great Results, Personable, Good Value.
"Czero understands technology development from the back-of-the-napkin stage to the product launch stage. I've never met a team who is more capable of keeping the end-product vision in mind during the early stages of engineering."
"Czero provided a custom engineering solution to our need to convey conceptual functionality. Their approach was creative, effective, high quality and fast. Highly endorsed."
"To work with Czero is nothing short of a privilege. Stemming from their excellent credentials and strong analytical aptitude, they consistently translate complex technical situations into plain English to allow multidisciplinary group to function together seamlessly."
"I was extremely impressed with how quickly Czero understood the needs and intent of the bearing housing design and how responsive they were in completing the drawing package."
Reach out to us, schedule a meeting, and let's find your custom solution.
We offer concept-to-prototype mechanical engineering R&D for developing systems and subsystems for cleantech innovations. Learn how we can help your team.