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Design Desk edition

Load/Path

New things engineers designed this week, and where you could fit into that work.

Issue
01·D
Week
21–25 Sep 2026
Designs
10
Build-it
2 projects
Read time
≈ 10 min

Somebody had to invent every one of these

Each design here started as a problem someone decided to solve differently. This edition focuses on what was built and the design choice that made it work. It also points to the problems still open, because those are the jobs of the next ten years.

  • The problemWhat was broken, slow or wasteful
  • The design moveThe one idea that made it work
  • Still unsolvedThe open problem, and the job opening
  • Where you fitDisciplines and skills that do this work
core discipline supporting role
The career map: which branches of engineering each design needs. Most need three or more. Scroll sideways on a phone.

New ways to make energy

Heat, fuel and water, rethought from the hardware up.

GeothermalDrilling

Drilling with microwaves to reach 400 °C rock

Geothermal power works brilliantly where hot rock sits near the surface, which is almost nowhere. Go deep enough and it's hot everywhere, but mechanical drill bits wear out in hard, hot rock long before they get there.

Quaise Energy's answer is to stop grinding and start melting. Its drilling approach uses millimetre-wave energy, the kind produced by fusion-research gyrotrons, to melt and vaporise rock. This week the US Department of Energy picked its Project Obsidian, south of Bend, Oregon, for up to $25m. The target is wells above 752 °F (400 °C) and reservoirs above 572 °F (300 °C). Three test wells should give 25 MW or more, scaling to 50 MW by 2030. A confirmation well is being drilled now.

Power generationStartup

A bolt-on power plant a tenth the size of steam

About 140 GW of US gas turbines run "simple cycle": they burn gas, spin, and dump hot exhaust into the sky. Adding a steam cycle to recover that heat is well understood, but it's big, slow to build and needs re-permitting.

Denver startup American Supercritical, just out of stealth with $8m, runs its second cycle on CO₂ above its critical point (31 °C, 73.8 bar), where it is as dense as a liquid. Denser fluid means smaller turbines and heat exchangers, about a tenth the footprint of steam kit, the company says. The block bolts onto the exhaust with no turbine changes and, by the company's figures, lifts output up to 50% on the same fuel.

Ocean engineeringNuclear fuel

Mining the sea for 4.5 billion tonnes of uranium

The oceans hold roughly 4.5 billion tonnes of dissolved uranium, at a vanishingly low concentration. Chemists have made adsorbent materials that grab it. The unsolved half is mechanical: put huge amounts of that material in the sea, leave it there, get it back and do it again.

SuperCritical Materials has partnered with the University of Michigan, led by mechanical engineer Maha Haji, to tackle exactly that. In the Aaron Friedman Marine Hydrodynamics Laboratory they'll measure how the adsorbent behaves under offshore loads and design prototype deployment and retrieval systems.

WaterSurface engineering

A solar still that leaves salt as a solid

Desalination has two nagging design faults. Salt crusts over evaporators and kills their efficiency, and the leftover brine harms marine life when it's pumped back out.

Chunlei Guo's team at the University of Rochester laser-treats metal until it is black and "superwicking", so water races across it. On the sun-heated centre, seawater evaporates. The coffee-ring effect, the reason a spilled coffee dries with a dark edge, carries the salt out to the cooler edges, where it collects as a solid. Tests with real seawater from several oceans ran without efficiency loss and recovered nearly all the salt. Published in Light: Science & Applications and J. Mater. Chem. A.

Machines that move and think

Small robots and fast light.

RoboticsControls

Teaching a paperclip-weight robot to do backflips

MIT's flapping-wing microrobot, driven by soft artificial muscles, had the hardware to fly like an insect but a hand-tuned controller that made it fly like a nervous drone. The controller that could fly it well was too heavy to compute in real time.

Kevin Chen's and Jonathan How's groups ran the heavy, robust model-predictive controller offline, then trained a small neural network to imitate it. The student runs fast enough to fly. Result: 447% faster, 255% more acceleration, and ten somersaults in 11 seconds while holding within 4–5 cm of its path. The goal is robots that can search earthquake rubble where quadcopters can't fit.

PhotonicsResearch

Steering one laser beam with another in 74 femtoseconds

Most optical switches work by exciting electrons and waiting for them to settle, which caps speed at picoseconds or slower. Harry Atwater's Caltech group went around that. A patterned pump pulse briefly changes silicon's refractive index through the optical Kerr effect, which needs no waiting, and a second beam passing through bends by up to 13°.

The Kerr effect is feeble, so the team patterned amorphous silicon with sub-wavelength nanopillars that trap light long enough to amplify it. Switching speed was limited only by the 74 fs laser pulse. Published in Nature Nanotechnology.

Better ways to make things

Chips, batteries and concrete, redesigned at the process level.

SemiconductorsNow in production

A chip film that fills the gap and flattens itself

3D chips are full of deep, narrow trenches. The carbon films used to pattern them follow every bump beneath, so fabs have to polish or etch the surface flat before the next step. Each extra step costs money and adds defects.

ASM International's XP8 Vertos Flowable Carbon, launched on 22 September, is deposited by PECVD but behaves like a liquid. It flows into trenches from the bottom up without voids or seams and settles flat on top. ASM says it's already in high-volume production for logic and memory.

BatteriesResearch

Delete the anode, keep the range

"Anode-free" lithium cells drop the graphite anode entirely and plate lithium straight onto copper foil. That saves weight and volume, but lithium tends to grow into needle-like dendrites that short the cell.

A KAIST team borrowed a chip-making technique, secondary sputtering lithography, to pattern copper foil with tube-shaped structures 300 nm wide and 150 nm high, then coated them with 10 nm of MXene. The patterning gives about four times the surface area and guides lithium to plate evenly. Published in Advanced Functional Materials on 1 September.

Circular manufacturingIn production

New EVs built from old EVs

GM and Cirba Solutions dismantled end-of-life GM packs, shredded them into "black mass" in Ohio, and refined it back to battery grade. The cathode material in the new cells contains 100% recycled nickel, cobalt and manganese. The first cars carrying those cells left Factory ZERO and Spring Hill this month.

Civil materialsLab stage

Concrete that gets stronger as it soaks up CO₂

Engineers at India's Mepco Schlenk Engineering College replaced half the fine aggregate in M35 concrete with porous zeolite and 1% of the cement with bamboo biochar. Compressive strength rose 7.48% to 38.49 MPa, and the mix absorbed 1.2 g of CO₂ a day in a test chamber. The paper dates from 2024 and is circulating again this week.

Three design moves to steal

The same patterns turn up again and again. Try them on your next project.

Change the medium

Keep the cycle and swap what flows through it or what does the cutting. Everything downstream changes size.

This week: CO₂ for steam · millimetre waves for drill bits

Borrow from next door

Import a tool that's mature in another industry. The fusion lab, the chip fab and the wave tank are full of them.

This week: chip lithography in battery foil · gyrotrons in drilling

Make physics do the chore

Choose a material or geometry so the unwanted step happens by itself.

This week: coffee-ring salt removal · self-levelling carbon film

Build it yourself

Two projects that started on a workbench.

Student project → real experiments

The $100 particle detector

Spencer Axani built CosmicWatch in 2017 as an MIT grad student, as a cheap way to teach particle physics. It counts muons, the cosmic particles passing through you right now. It's now used in the NuDot experiment and the CAPTAIN-Mills dark matter detector at Los Alamos, and a spacecraft version is in development. Version 3 is open and documented.

Cost ≈ $100 in parts · Skills PCB assembly, embedded code, data analysis · CosmicWatch site ↗

Maker build · experimental

A skip-find AC turned ground-source heat pump

YouTuber Craftsman Chris rotated the condenser coil of a salvaged 14,000 BTU window unit, wrapped it in a sheet-metal water jacket and ran it through about 2,000 ft of buried PEX (four 500 ft loops, 6–8 ft deep) under PLC control. Supply air came out at 49–54 °F. He's clear it needs better protection and data before real use, and you should treat refrigerant and mains wiring with respect.

Skills refrigeration cycle, PLC logic, heat-exchanger design · Full story ↗

Your homework

  • Pick one "Still unsolved" box above. Write down three companies or labs working on it. That's a job search list.
  • Take a project you're on now. Which of the three design moves could you try on it?

More new designs this week