Case Studies

See how organizations use ThalosForge to solve complex optimization, MLOps, and robotics challenges.

Optimization

Aerospace Wing Design Optimization

Aerospace Engineering • CFD Simulation

The Challenge

An aerospace company needed to optimize wing geometry for fuel efficiency. Each CFD simulation took 4 hours and cost $200 in compute. Traditional optimization required 500+ simulations, making the project economically unfeasible.

The Solution

Using Spiral Swarm DSS, the team reduced the required simulations from 500+ to just 120 while achieving better final results. DSS's deterministic nature also meant results were reproducible for regulatory documentation.

78%
Fewer Simulations
$76K
Compute Savings
3.2%
Fuel Efficiency Gain
100%
Reproducible
"DSS found a better design in 120 simulations than our previous approach found in 600. The deterministic results made FAA documentation straightforward."
— Chief Aerodynamics Engineer
MLOps

Fraud Detection Model Maintenance

Financial Services • Machine Learning Operations

The Challenge

A major bank's fraud detection model degraded every 6-8 weeks as fraudsters adapted their tactics. Each retraining cycle cost $35,000 and took the ML team 2 weeks. False positive rates climbed 40% between retraining cycles, blocking legitimate transactions.

The Solution

Saturna was deployed as a calibration maintenance layer on top of the existing fraud model. It automatically corrects for drift, maintaining model accuracy without retraining.

0
Retraining Cycles/Year
$210K
Annual Savings
45%
False Positive Reduction
12+
Weeks Between Reviews
"We went from fire-fighting model degradation every month to quarterly reviews. Saturna paid for itself in the first 6 weeks."
— Head of ML Platform
Robotics

Precision Assembly Robot Smoothing

Electronics Manufacturing • Industrial Automation

The Challenge

An electronics manufacturer's pick-and-place robots had jerky motion causing component misalignment. Rejected units ran at 2.3%, and the mechanical oscillation was causing premature servo wear requiring $15K maintenance every 6 months.

The Solution

Command Dosage Control was deployed as a software layer between the motion planner and motor controllers. No hardware changes were required. The system learned optimal dosing parameters for each robot within 2 hours of operation.

0.4%
Rejection Rate (was 2.3%)
83%
Defect Reduction
18mo
Maintenance Interval (was 6mo)
0
Hardware Changes
"We thought we'd need new servos. Command Dosage fixed the problem with a software update. ROI in under 3 months."
— Manufacturing Engineering Manager
Optimization

Neural Network Hyperparameter Tuning

Technology • Machine Learning

The Challenge

An ML team needed to tune a transformer model with 47 hyperparameters. Grid search was impossible (10^47 combinations), and Bayesian optimization struggled with the high dimensionality. Each training run took 6 hours on 8 GPUs.

The Solution

QuantumJolt optimized all 47 hyperparameters simultaneously, finding better configurations in 80 trials than the team had achieved in 6 months of manual tuning.

47
Hyperparameters Tuned
80
Training Runs (was 200+)
2.1%
Accuracy Improvement
$48K
GPU Cost Savings
"QuantumJolt found a configuration we never would have tried manually. The 2.1% accuracy gain translated to $2M annual revenue impact."
— Principal ML Engineer
MLOps

Medical Diagnostic Device Calibration

Healthcare • Medical Devices

The Challenge

A diagnostic device manufacturer faced costly recalibration requirements. Each device needed field service every 3 months at $8,000 per visit. FDA documentation required full audit trails of calibration state.

The Solution

Saturna was embedded in the device firmware to maintain sensor calibration automatically. The audit trail feature satisfied FDA documentation requirements without manual intervention.

12mo
Service Interval (was 3mo)
$24K
Saved Per Device/Year
100%
FDA Audit Compliance
0.98
Stability Index Maintained
"Saturna transformed our service model. Devices stay calibrated, customers are happier, and our service costs dropped 75%."
— VP of Product Engineering

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