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Design Desk edition

Load/Path

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

Issue
06·D
Week
26–30 Oct 2026
Designs
9
Build-it
2 projects
Read time
≈ 10 min

Nine new designs, from a viaduct pushed over a motorway to a heart patch with no electronics

A lot of this week's designs are about not getting in the way. HS2 built a viaduct over the M6 without shutting it. Network Rail squeezed six months of weekend work into 18 days. A Dutch crew buries power cables under a lake and leaves it free for summer. For each design we show what was built and the idea that made it work. We also show what is still unsolved, because that is where the next jobs are.

  • The problemWhat was broken, slow, dangerous 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.

Build it without stopping everything

A viaduct pushed over live traffic, a railway rebuilt in one go, and cables laid under a lake that stays open for summer.

Rail · UKStructure complete

A 320 m viaduct pushed over the M6 with the traffic still running

HS2 has to cross the M6 near Birmingham, one of the busiest stretches of motorway in the country. Closing it for weeks to lift in a bridge was not an option.

So the contractor, Balfour Beatty VINCI, built each steel deck in sections behind one end of the crossing. Strand jacks, hydraulic jacks that pull on bundles of steel cable, then hauled the deck out over the road in stages. Each push added length at the back and moved the front further across. The west deck went over in four stages; the last one moved it 76 m in nine hours, on 24 October. There are two decks, each 320 m long, sitting 100 mm apart on concrete piers. The M6 stayed open the whole time.

Rail electrification · ScotlandUnder construction

Six months of weekend railway work, done in 18 days

To run electric trains in Fife, Network Rail must put up overhead wires. Bridges over the line have to be raised to make room for them. That kind of work is usually done in short weekend closures, over many months.

Instead, Network Rail shut the line for 18 days in one go, from 10 to 27 October. Many jobs ran at the same time, day and night. Crews knocked down three bridges and put in 29 concrete beams for higher replacements. They put in more than 200 foundations for the overhead-line masts, replaced 26 pieces of old signalling equipment and cleared more than 209,000 m² of vegetation. Network Rail says this was up to six months of weekend work. The scheme is part of £311.5m to electrify 118 km of railway.

Grid connections · NetherlandsUnder construction

Burying power cables under a lake by turning the sand to liquid

Power from two new offshore wind zones has to come ashore in the Netherlands. The cable route crosses the Veerse Meer, a lake used for water sports.

The marine contractor DEME, working with cable maker Prysmian for grid operator TenneT, built a custom pontoon for the job. It carries reels of cable and lays the high-voltage cable, spare cables and a fibre-optic line at the same time. High-pressure water jets briefly turn the sand underneath into a fluid, so the cables sink to at least 3 m deep. The sand then settles back behind the pontoon. The contractor says this keeps the water from clouding up. Work runs until spring 2027 and is timed to leave the lake free in summer.

Energy hardware, built a new way

Solar wings that unroll by themselves, reactors made in shipyards, and LEDs small enough to carry data.

Space · US / CanadaInstalled

Solar wings that unroll with no motors

The International Space Station's original solar wings were fitted between 2000 and 2009, and they are wearing out. NASA is adding new ones rather than replacing them.

On 29 October, astronauts Anil Menon of NASA and Joshua Kutryk of the Canadian Space Agency fitted the seventh of eight roll-out arrays. The spacewalk took 7 hours 11 minutes. Each array is about 18 m (60 ft) long and makes about 8 kW. It sits in front of an old wing, and the parts of the old wing it doesn't shade keep working. Once released, the array unrolled in about 10 minutes with no motors, driven by energy stored in its bent carbon-fibre booms. NASA says all eight together raise the station's power from 160 kW to about 215 kW.

Nuclear · USProposal

A plan to build nuclear plants in shipyards, and run them on gas first

New nuclear plants are often late and over budget, which makes them hard to fund. Blue Energy, a start-up founded by an MIT graduate, wants to change how they are built and paid for.

Its idea has two parts. First, make the plant in shipyards as "Blue Blocks" of about 1,360 tonnes (1,500 US tons) each, then float them to the site on barges. The company says a unit could be assembled in about a year. Second, start the plant on gas. Gas turbines would make steam for the plant's own steam turbines, so it can be financed like a gas plant. The reactors come later. Its first project, in Victoria, Texas, would start with 1 GW of gas power in 2030. Up to five small reactors, adding 1.5 GW, would follow from 2032. Blue Energy filed the first part of its construction application with the US regulator in September.

Photonics · USLab

Shrinking an LED until it can carry data at record speed

Inside AI data centres, chips swap huge amounts of data over copper wires. Copper is struggling to keep up on power, heat and speed. Light could carry the data instead, but the light source has to switch on and off very fast.

Engineers at the University of Illinois Urbana-Champaign tested blue gallium nitride micro-LEDs from 100 µm down to 2 µm across. Smaller LEDs have less capacitance, so they charge and discharge faster, and that sets how fast they can switch. A 5 µm LED reached a record modulation bandwidth of 2.75 GHz. That is roughly how fast its brightness can be varied to carry data. Below 5 µm, resistance in the electrical contacts rose and the LEDs matched badly to standard 50 Ω circuits.

Sense it, then act on it

A patch your phone can read, an implant that switches itself on, and drones that plan for quiet.

Health monitoring · NorwayResearch prototype

A heart-monitoring patch with no electronics at all

Smartwatches measure pulse by shining light into the skin. Their optical sensors are less accurate on darker skin, and they need batteries and circuits.

Researchers at NTNU, the Norwegian University of Science and Technology, made a thin, clear patch of silicone rubber with no electronics. One side has a nano-scale pattern that changes colour when it stretches. Each pulse stretches the skin slightly, and a smartphone camera reads the colour change. A 2% stretch gives a 9% change in colour intensity. The other side has tiny suction cups, inspired by octopus suckers, which grip 65% better than flat silicone. In tests on 13 volunteers, the readings closely matched clinical equipment. The team says it could also measure how stiff the arteries are, which smartwatches struggle with. Because it reads movement, not light through skin, skin colour should matter less.

Medical devices · SwitzerlandAnimal study

An implant that burns off excess blood sugar when your phone says so

Insulin lowers blood sugar by pushing glucose into cells, but it doesn't remove the extra energy. Earlier approaches relied on genetically engineered biological parts.

A team at ETH Zurich used chemistry and electronics instead. The implant is graphite felt coated with gold and platinum particles. When it is switched on, it turns glucose into gluconate, which the body passes out in urine. A sensor on the upper arm sends glucose readings by Bluetooth to a phone or watch. That switches the implant on, using wireless power at 13.56 MHz, and off again at the target level. In diabetic mice over six weeks, it controlled glucose with no tissue damage.

Drones · USCompany claim

Delivery drones that plan their flight around noise

Noise is one of the main complaints about delivery drones. Zipline says it has made its fixed-wing drones quieter mainly by changing how they fly.

Each drone carries wind sensors and an acoustic model. It plans its climb, cruise and descent to use gravity and wind, rather than its motors, to speed up and slow down. In cruise it can shut down all but one motor. Zipline's own modelling says this and other changes cut the sound people hear per flight by 68%, compared with its 2025 fleet. Peak loudness fell by 24%. It says the flying method alone cut energy per flight by 21%. No decibel figures or independent measurements were published.

Three design moves to steal

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

Build it somewhere easier

Do the hard work where conditions are good, then move the finished thing into place.

This week: a viaduct built beside the M6, then pushed over · reactor blocks made in shipyards

Bunch the disruption

Sometimes one planned interruption costs less than many small ones. Pick when it happens.

This week: 18 days in Fife instead of six months of weekends · lake work kept out of summer

Let physics do the job

Before adding a motor or a circuit, check whether gravity, stored energy or the material itself can do it.

This week: solar wings that unroll on spring energy · a patch that turns strain into colour · drones gliding on gravity

Build it yourself

One for the workbench, one for your CV.

Bench project · Structures

Test a tape measure as a space boom

The space station's new arrays unroll using energy stored in bent carbon-fibre booms. A steel tape measure works in a related way: its curved cross-section makes it stiff when it's straight, yet it rolls up flat. Slide the tape out horizontally, curve facing up, and measure how far it goes before it buckles and drops. Then try it curve-down. Which way is longer, and why? Sketch the cross-section and think about its second moment of area. Bonus: tape two tapes back to back and try again.

Skills buckling, second moment of area, stored strain energy · The ISS arrays ↗

Competition · International · Students

Design a robot for a crowded public space

The Human-Robot Interaction (HRI) 2027 Student Design Competition wants a robot for a real public place full of bystanders. Teams of two to five students can enter, from undergraduate to PhD, in any discipline. Your design must deal with a complication such as crowding, noise or accessibility. You submit a paper of up to four pages and, if you like, a video of up to three minutes. Sketches and rough prototypes are fine. The deadline is 23:59 on 20 November 2026, Anywhere on Earth time.

Skills user-centred design, robotics, technical writing · Competition details ↗

Your homework

  • Think of a job on your course or at work that gets done in many small chunks. Would one longer block be better? List what you'd gain and what you'd risk, like Network Rail did in Fife.
  • The NTNU patch turns 2% strain into a 9% colour change. Find another everyday material that changes in a way you can see or hear when it's loaded. Could a phone measure it?

More new designs this week

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