Project "Frank" — High-Integrity Underwater Enclosure

Project Overview & Objective

Brae Systems required a functional physical proof-of-concept (PoC) to secure critical funding milestones for their data center infrastructure program. The objective was the development of "Frank," an underwater enclosure designed to house and protect mission-critical pumps, electronics, and supporting hardware. Taking the project from a preliminary conceptual stage, the engineering focus was on delivering a sealed, operational unit that met rigorous performance requirements.

Design Strategy & Geometry Optimization

The primary design challenge centered on balancing structural demands with manufacturability. An octagonal cross-section was selected to optimize structural rigidity and internal volumetric efficiency while maximizing the available sealing surface area. This geometry allowed for efficient flat-pattern rolling and fabrication using standard tooling. Every face of the octagonal profile was engineered to accommodate external connector penetrations and a removable access panel for hardware integration.

Engineering Constraints & Sealing Integration

Ensuring a high-integrity seal was a critical constraint given the immersion environment. Engineering rigor was applied to maintaining precision tolerances across all mating faces and connector interfaces. Through iterative development of gasket geometry, fastener patterns, and surface preparation protocols, a reliable, hermetic seal was achieved. The solution eliminated the need for specialized auxiliary equipment, demonstrating a robust approach to industrial sealing and integration.