Pressure Regulating Controller

Flight-ready regulator. Proven-performance in extremes.

After our review of the initial design revealed vulnerabilities, we helped redesign, test for extremes and pass certification.

  • Rapid Delivery of working concept design
  • MIL-STD Compliance with MIL-STD-461 and MIL-STD-810
  • 100% Units advancing to environmental testing

Designed to deliver

Revised board layout for stable performance

The circuit board was redesigned to withstand harsh conditions and meet MIL-STD-461 and MIL-STD-810 standards, ensuring stable performance in demanding environments.

Firmware-controlled sensor diagnostics

Custom firmware monitors sensor readings in real time, detects pressure anomalies, and triggers safe responses under voltage swings or extreme conditions.

Strengthened valve interface geometry

We reinforced the valve housing and mounting points to withstand continuous vibration and rapid pressure changes without loosening or wear.

Results that make a difference

  • Added confidence: Our redesign of the firmware and electronics delivered a flight-ready controller so JASC could enter environmental testing with assurance in its performance.
  • Faster path to certification: We delivered a redesigned, test-ready controller in weeks, helping JASC move quickly into environmental testing without delays.
  • Faster production start: Working closely with 29Tech meant the design was ready for manufacturing from day one, helping JASC move toward validation and scaling without delays.

Project overview

Certifying a controller for high-stakes uses

JASC developed a digital pressure-regulating controller for aerospace use. This compact system keeps fluid pressure steady in high-stakes environments, from placing satellites to guiding unmanned craft. Before moving to testing, they asked 28 Gorilla to review its readiness for certification.

The original board layout, firmware logic and valve interface left the system vulnerable to heat, electrical drift and unstable feedback. Any of these could cause failure in flight. We quickly delivered a new concept that addressed the most urgent risks. That depth of review earned us the lead engineering role for the rest of development.

Working closely with JASC and our integrated manufacturing partner, 29Tech, we redesigned the board and firmware for durability under vibration and pressure swings. The result was a controller ready for environmental testing.

The challenge

Review for readiness

When flight safety depends on steady pressure, even small design flaws can have big consequences. The original controller had never been tested under aerospace-level strain, so it wasn’t proven for extreme temperatures, pressure changes or sustained vibration. Our challenge was to find what might fail, redesign it to survive, and do it fast enough to keep an accelerated test schedule on track.

Our approach

Assess and adapt quickly

We started with a full review of the electrical design and control logic, reworking the board layout to reduce heat buildup and improve signal stability. We rewrote the firmware to read sensor data in real time, react to abnormal conditions and keep the valve operating within tight limits.

By collaborating early with 29Tech, we ensured the controller was ready for real-world testing without delays, rework or translation-loss between design and manufacturing.

Skills & equipment used

  • Industrial product design:

    • Compact board architecture
    • Mounting flexibility
    • Ruggedized interfaces
    • SolidWorks, 3D printing, prototyping tools

  • Electrical engineering design:

    • Signal stability
    • EMI resilience
    • High-temperature component selection
    • Altium
    • Oscilloscopes, harnessing tools

  • Mechanical engineering:

    • Vibration-resistant mounting
    • Strain relief design
    • CAD modeling
    • Stress analysis tools

  • Firmware development:

    • Real-time sensor monitoring
    • Fault detection logic
    • Precision valve control
    • C/C++
    • Microcontroller dev boards
    • Bench testing

  • Software product development.

  • Product concept development:

    • Requirements shaping
    • Early-stage risk reduction
    • Concept-to-prototype transition
    • Napkin sketch to CAD