// ENG-CELL OPS - RAPID CITY · TX · MT · NE

ShawsShanks Engineering

360° engineering - software, AI, robotics, and the hands that bolt them to the factory floor. We don't consult from a hotel room. We deploy from a shop in Rapid City.

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ShawsShanks Engineering
// 01 - SYSTEM LAYER

Full Stack. Embedded. Cloud.

Custom builds and surgical replacements - designed from scratch or vendor stack rip-outs. Bare-metal firmware to cloud-scale data pipelines. Python, C++, Rust, Go, whatever the job demands.

Domains we specialize in: automotive engineering and race-car telemetry | internal combustion engine design and tuning | frequency harmonics and vibration analysis | aerospace systems | UAV / drone fleets | and similarly sensitive industries.

While these are our mission-critical specializations, the lessons learned in environments where failure isn't an option transfer directly. We apply that same discipline to any field where engineering precision matters.

Production code on production hardware. Pushing 100k samples/sec from sensor edge to cloud.

SYSTEM
CPU LOAD
38.6%
Intel Core i9 - 32 threads
MEMORY
11.2 GB
16 GB total - 4.8 GB free
PROCESSES
714 total
8 running · 706 sleeping
COMMANDCPUMEM
sse-vision24.1512M
robot-ctrl18.4228M
plc-bridge12.296M
data-ingest8.7184M
api-server4.172M
cam-proc3.9320M
MAIN - bash
shawsshanks@sse-dev:~$ uname -a
Linux sse-dev 6.6.14-rt-amd64 #1 SMP PREEMPT_RT x86_64 GNU/Linux
 
shawsshanks@sse-dev:~$ uptime
14:32:17 up 847 days, 22:09, 4 users, load avg: 0.12 0.18 0.24
 
shawsshanks@sse-dev:~$ cat capabilities.txt
== SOFTWARE ENGINEERING STACK ==
LANGUAGES Python · C++ · Rust · Go · TypeScript · ASM
EMBEDDED STM32 · ESP32 · RPi · RTOS · FPGA
CLOUD AWS · Azure · Docker · K8s · Terraform
DATABASES PostgreSQL · InfluxDB · Redis · MQTT
 
shawsshanks@sse-dev:~$ sudo nmap -sS -A 192.168.4.0/24
[INFO] Scanning local subnet...
[+] 192.168.4.21 UR10e robot SSH:open
[+] 192.168.4.42 HAAS VF-2 PLC OPC:open
[+] 192.168.4.50 Cognex cam HTTP:open
[+] 192.168.4.99 Spindle VFD MODBUS:open
 
shawsshanks@sse-dev:~$ ssh -i ~/.ssh/legacy_key root@192.168.4.42
Welcome to HAAS Operator Console v4.21
[OK] Authenticated as root · Cycle 1247 in progress
 
shawsshanks@sse-dev:~$ ./run_deploy.sh --target=prod
[INFO] Building sse/vision-core:2.4.1
[INFO] Test suite ... PASSED (247/247)
[INFO] Pushing to registry ...
[OK] Deploy complete · 0 downtime
 
shawsshanks@sse-dev:~$ tail -f /var/log/plc-bridge.log
12:44:08 PLC connected: HAAS VF2 [192.168.1.101]
12:44:09 Spindle ON: 7500 RPM nominal
12:44:11 Axis X: 2.4502 Y: 0.0000 Z:-0.2500
12:44:14 Part complete: robot signal sent
12:45:02 Tool change T1 -> T2
12:45:10 New part loaded: vision check OK
 
shawsshanks@sse-dev:~$ python3 vision_check.py
Loading: sse_defect_v3.onnx ... OK
Camera 0: 1920x1080 @ 60fps ... ONLINE
Camera 1: 1920x1080 @ 60fps ... ONLINE
Inference latency: 12ms ....... PASS
 
shawsshanks@sse-dev:~$ git log --oneline -n 8
a4f3e2b fix: spindle PID overshoot at 8500 RPM
b8c1d4f add: hydraulic pressure sensor calibration
c9e0f5a chore: bump ros2 jazzy 0.5.3
d1a2b3c fix: knock detector false positives
e4f5g6h wip: blackbird telemetry decoder
f5g6h7i fix: race condition in part-complete signal
g6h7i8j feat: live OEE dashboard for line 3
h7i8j9k docs: update README for new techs
 
shawsshanks@sse-dev:~$ docker ps
CONTAINER ID IMAGE STATUS
a1b2c3d4 vision-core:2.4 Up 47h
b2c3d4e5 data-pipe:latest Up 12d
c3d4e5f6 grafana:11.1.0 Up 12d
d4e5f6g7 timescale:2.14 Up 12d
e5f6g7h8 mqtt-broker:2.0 Up 12d
 
shawsshanks@sse-dev:~$ kubectl get pods -n production
sse-vision-7d8f9-xkn2 1/1 Running
robot-ctrl-9f8e7-mq4r 1/1 Running
plc-bridge-4c5d6-bn8p 1/1 Running
data-ingest-7e8f9-kp4n 2/2 Running
 
shawsshanks@sse-dev:~$ cat ./notes/lab_journal.md
# Engineering Notes - week 17
- finish vision calibration for line 3
- order more carbide endmills (last 12mm broke)
- email client about prototype delivery (overdue)
- Last week we put liquid paper on a bee ... it died
- note to self: do not repeat experiment
- update firmware on robot 7
- coffee. coffee is critical infrastructure
- spindle harmonics humming 'Funkytown' at 3741Hz
- client wants 'just add AI to it'. charge accordingly
 
shawsshanks@sse-dev:~$ openssl rand -hex 16
e7a8b3c5d2f1648e9012c4ab7d3e6f81
 
shawsshanks@sse-dev:~$ ./check_machines.sh
[OK] CNC-01 online cycle 1247
[OK] CNC-02 online idle
[OK] CNC-03 online cycle 442
[OK] CNC-04 online cycle 88
[*] ROBOT-01 active (tending CNC-01)
[*] ROBOT-02 active (tending CNC-03)
 
shawsshanks@sse-dev:~$ free -h
total used free available
Mem: 32Gi 11.2Gi 14.3Gi 20.1Gi
 
shawsshanks@sse-dev:~$ python3 -c "import sse; sse.production.status()"
{'cells_active': 4, 'parts_today': 2841, 'oee': 0.924}
 
shawsshanks@sse-dev:~$ ./failsafe.sh --status
[INFO] E-stop: ARMED
[INFO] Light curtain: ACTIVE
[INFO] Door interlock: CLOSED
[OK] All interlocks: HEALTHY
 
shawsshanks@sse-dev:~$ history | tail -5
ssh root@haas-vf2
./calibrate_vision.sh --camera 1
vim TODO.md
./deploy.sh --target prod
echo "shipping."
 
shawsshanks@sse-dev:~$ echo "shipping."
shipping.
 
shawsshanks@sse-dev:~$ uname -a
Linux sse-dev 6.6.14-rt-amd64 #1 SMP PREEMPT_RT x86_64 GNU/Linux
 
shawsshanks@sse-dev:~$ uptime
14:32:17 up 847 days, 22:09, 4 users, load avg: 0.12 0.18 0.24
 
shawsshanks@sse-dev:~$ cat capabilities.txt
== SOFTWARE ENGINEERING STACK ==
LANGUAGES Python · C++ · Rust · Go · TypeScript · ASM
EMBEDDED STM32 · ESP32 · RPi · RTOS · FPGA
CLOUD AWS · Azure · Docker · K8s · Terraform
DATABASES PostgreSQL · InfluxDB · Redis · MQTT
 
shawsshanks@sse-dev:~$ sudo nmap -sS -A 192.168.4.0/24
[INFO] Scanning local subnet...
[+] 192.168.4.21 UR10e robot SSH:open
[+] 192.168.4.42 HAAS VF-2 PLC OPC:open
[+] 192.168.4.50 Cognex cam HTTP:open
[+] 192.168.4.99 Spindle VFD MODBUS:open
 
shawsshanks@sse-dev:~$ ssh -i ~/.ssh/legacy_key root@192.168.4.42
Welcome to HAAS Operator Console v4.21
[OK] Authenticated as root · Cycle 1247 in progress
 
shawsshanks@sse-dev:~$ ./run_deploy.sh --target=prod
[INFO] Building sse/vision-core:2.4.1
[INFO] Test suite ... PASSED (247/247)
[INFO] Pushing to registry ...
[OK] Deploy complete · 0 downtime
 
shawsshanks@sse-dev:~$ tail -f /var/log/plc-bridge.log
12:44:08 PLC connected: HAAS VF2 [192.168.1.101]
12:44:09 Spindle ON: 7500 RPM nominal
12:44:11 Axis X: 2.4502 Y: 0.0000 Z:-0.2500
12:44:14 Part complete: robot signal sent
12:45:02 Tool change T1 -> T2
12:45:10 New part loaded: vision check OK
 
shawsshanks@sse-dev:~$ python3 vision_check.py
Loading: sse_defect_v3.onnx ... OK
Camera 0: 1920x1080 @ 60fps ... ONLINE
Camera 1: 1920x1080 @ 60fps ... ONLINE
Inference latency: 12ms ....... PASS
 
shawsshanks@sse-dev:~$ git log --oneline -n 8
a4f3e2b fix: spindle PID overshoot at 8500 RPM
b8c1d4f add: hydraulic pressure sensor calibration
c9e0f5a chore: bump ros2 jazzy 0.5.3
d1a2b3c fix: knock detector false positives
e4f5g6h wip: blackbird telemetry decoder
f5g6h7i fix: race condition in part-complete signal
g6h7i8j feat: live OEE dashboard for line 3
h7i8j9k docs: update README for new techs
 
shawsshanks@sse-dev:~$ docker ps
CONTAINER ID IMAGE STATUS
a1b2c3d4 vision-core:2.4 Up 47h
b2c3d4e5 data-pipe:latest Up 12d
c3d4e5f6 grafana:11.1.0 Up 12d
d4e5f6g7 timescale:2.14 Up 12d
e5f6g7h8 mqtt-broker:2.0 Up 12d
 
shawsshanks@sse-dev:~$ kubectl get pods -n production
sse-vision-7d8f9-xkn2 1/1 Running
robot-ctrl-9f8e7-mq4r 1/1 Running
plc-bridge-4c5d6-bn8p 1/1 Running
data-ingest-7e8f9-kp4n 2/2 Running
 
shawsshanks@sse-dev:~$ cat ./notes/lab_journal.md
# Engineering Notes - week 17
- finish vision calibration for line 3
- order more carbide endmills (last 12mm broke)
- email client about prototype delivery (overdue)
- Last week we put liquid paper on a bee ... it died
- note to self: do not repeat experiment
- update firmware on robot 7
- coffee. coffee is critical infrastructure
- spindle harmonics humming 'Funkytown' at 3741Hz
- client wants 'just add AI to it'. charge accordingly
 
shawsshanks@sse-dev:~$ openssl rand -hex 16
e7a8b3c5d2f1648e9012c4ab7d3e6f81
 
shawsshanks@sse-dev:~$ ./check_machines.sh
[OK] CNC-01 online cycle 1247
[OK] CNC-02 online idle
[OK] CNC-03 online cycle 442
[OK] CNC-04 online cycle 88
[*] ROBOT-01 active (tending CNC-01)
[*] ROBOT-02 active (tending CNC-03)
 
shawsshanks@sse-dev:~$ free -h
total used free available
Mem: 32Gi 11.2Gi 14.3Gi 20.1Gi
 
shawsshanks@sse-dev:~$ python3 -c "import sse; sse.production.status()"
{'cells_active': 4, 'parts_today': 2841, 'oee': 0.924}
 
shawsshanks@sse-dev:~$ ./failsafe.sh --status
[INFO] E-stop: ARMED
[INFO] Light curtain: ACTIVE
[INFO] Door interlock: CLOSED
[OK] All interlocks: HEALTHY
 
shawsshanks@sse-dev:~$ history | tail -5
ssh root@haas-vf2
./calibrate_vision.sh --camera 1
vim TODO.md
./deploy.sh --target prod
echo "shipping."
 
shawsshanks@sse-dev:~$ echo "shipping."
shipping.
 
shawsshanks@sse-dev:~$█
NETWORK
State
IPv4 ONLINE
Endpoint
192.168.1.50
Ping
2ms
Up / Down
24.8 / 187.2 MB/s
PLC Bridge
HAAS LIVE
Robot Link
UR10e LIVE
Vision
2 CAM LIVE
Cloud Sync
AWS ACTIVE
TELEM // SENSOR-FUSION - B-1B LANCER / TFR LOW-LEVEL STRIKE● LIVE
QUAD F101-GE-102 TURBOFAN
ENG1
N1 94.2%
ENG2
N1 93.6%
ENG3
N1 94.1%
ENG4
N1 92.8%
EGT AVG687°C
THRUST112,800 lbs
A/B2 ENGAGED
WING SWEEP - VARIABLE GEOMETRY
SWEEP67.5°
MODEHI-SPEED
FLAPS0%
FUEL TANKS - INTERNAL
FWD MID AFT L WING R WING
FWD
15.6K
MID
27.6K
AFT
21.6K
L WING
44.6K
R WING
43.5K
TOTAL152.9K / 195K lb
CG47.2% MAC
TACTICAL DATALINK STREAM
14:32:08 AGL 187 ft
14:32:08 BARO 642 ft MSL
14:32:09 IAS 566 kts
14:32:09 GS 604 kts / M 0.92
14:32:10 SWEEP 67.5°
14:32:10 AOA +1.4°
14:32:11 HDG 287° / DRIFT 4°L
14:32:11 TFR SET 200 AGL
14:32:12 FUEL 72% / 54,300 lbs
14:32:12 WPT BRAVO-3 / 184 nm
14:32:13 ECM ACTIVE
14:32:13 RWR 2 contacts
14:32:14 BAY1 CLOSED / EMPTY
14:32:14 BAY2 LOADED B-61 x8
14:32:15 BAY3 LOADED JASSM x4
14:32:15 CHAFF 24 / FLARE 16
14:32:16 CABIN 8,000 ft
14:32:16 CREW 4 / NOMINAL
14:32:17 INS aligned / drift 0.4nm
14:32:17 XPDR 7700 EMCON
14:32:18 MISSION NIGHT-OWL / RUN-1
14:32:18 OAT -23°C
14:32:19 TANKER RDV +47 min
14:32:08 AGL 187 ft
14:32:08 BARO 642 ft MSL
14:32:09 IAS 566 kts
14:32:09 GS 604 kts / M 0.92
14:32:10 SWEEP 67.5°
14:32:10 AOA +1.4°
14:32:11 HDG 287° / DRIFT 4°L
14:32:11 TFR SET 200 AGL
14:32:12 FUEL 72% / 54,300 lbs
14:32:12 WPT BRAVO-3 / 184 nm
14:32:13 ECM ACTIVE
14:32:13 RWR 2 contacts
14:32:14 BAY1 CLOSED / EMPTY
14:32:14 BAY2 LOADED B-61 x8
14:32:15 BAY3 LOADED JASSM x4
14:32:15 CHAFF 24 / FLARE 16
14:32:16 CABIN 8,000 ft
14:32:16 CREW 4 / NOMINAL
14:32:17 INS aligned / drift 0.4nm
14:32:17 XPDR 7700 EMCON
14:32:18 MISSION NIGHT-OWL / RUN-1
14:32:18 OAT -23°C
14:32:19 TANKER RDV +47 min
CYL-BALANCE // TOYOTA 1GZ-FE V12 - PENNY-ON-BLOCK TEST● ACQUIRING
BANK A - CRANKSHAFT
CYL 1 vibration0.011 g RMS
CYL 3 vibration0.010 g RMS
CYL 5 vibration0.014 g RMS
BANK B - ENGINE BLOCK
BLOCK FRONT0.009 g RMS
BLOCK MID0.008 g RMS
BLOCK REAR0.012 g RMS
AVG PEAK84.21 bar
DEV (RMS)0.087 bar
DEV MAX0.30 bar
BALANCE99.94%
FUND.240.0 Hz
2ND HARM480.0 Hz
VIBR. RMS0.012 g
STATUSPENNY OK
PIKES PEAK // SUZUKI ESCUDO V6-TWIN - TAJIMA / 2001● LIVE
COURSE - 12.42 mi / 156 turns / 4,720 ft gain
14,110 SUMMIT 13,000 12,000 11,000 10,000 ft 9,390 START FINISH 14,110 DEVIL'S PLAYGROUND BOTTOMLESS PIT BOULDER PARK THE LEGS (1-4) GLEN COVE ELK PARK HALFWAY PICNIC BLUE SKY
POSITION
SECTOR3 / 4
ELEV12,840 ft
GRADE+8.4%
MILE8.4 / 12.42
SPEED87 mph
HEADING312°
THROTTLE92%
LAP5:38.412
DELTA▼ -3.142
PB10:53.46
ELEVATION PROFILE
9.4K 12K 14.1K M7 START SUMMIT
ENGINE 1 - FRONT V6 / TWIN TURBO
9,180 RPM
BOOST36.2 psi
OIL T122°C
EGT876°C
FUEL P95 psi
ENGINE 2 - REAR V6 / TWIN TURBO
9,210 RPM
BOOST36.4 psi
OIL T119°C
EGT869°C
FUEL P94 psi
CLIMB METRICS - THIN AIR
O265%
AIR T2°C
DENS0.62kg/m³
WIND14mph
TRACK T4°C / DRY
G-LAT1.8 g
G-LONG2.4 g
TRANSMISSION - AWD COMBINED
GEAR4 / 5-spd
CLUTCH T98°C
TRANS T108°C
DIFF FLOCKED
DIFF CLOCKED
DIFF RLOCKED
COMB HP1,250 hp
COMB TQ920 lb-ft
TIRESSLICKS / DOT-R
// 02 - KINETIC LAYER

AI & Robotics

Robot Deployment & Maintenance. UR / FANUC / KUKA integration onto Haas, Mazak, DMG MORI cells. Vision-guided pick & place. Predictive maintenance from sensor fusion.

HAAS · VF-2 UR10e DROPOFF BLANKS
HOMERETRIEVEDROPPICKINSERTRUN
URSCRIPT // CELL-04
# UR10e cell-04.urscriptdef tend_loop(): movej(home_q) # 01 open door set_do(0, True) # 02 grip finished movel(cnc_pose) set_tdo(0, True) # 03 retract movel(safe_pose) # 04 dropoff movej(drop_q) set_tdo(0, False) # 05 pick blank movej(bin_q) set_tdo(0, True) # 06 insert blank movel(insert_pose) set_tdo(0, False) # 07 close + run set_do(0, False) set_do(1, True)end # UR10e cell-04.urscriptdef tend_loop(): movej(home_q) # 01 open door set_do(0, True) # 02 grip finished movel(cnc_pose) set_tdo(0, True) # 03 retract movel(safe_pose) # 04 dropoff movej(drop_q) set_tdo(0, False) # 05 pick blank movej(bin_q) set_tdo(0, True) # 06 insert blank movel(insert_pose) set_tdo(0, False) # 07 close + run set_do(0, False) set_do(1, True)end
HAAS // O0042.NC
( CELL-04 O0042 )N10 G90 G94 G17 G20N20 G53 G00 Z0.N30 T1 M06N40 G54 X0 Y0 S6500 M03N50 G43 Z1. H01 M08N60 G00 X-.25 Y-.25N70 Z.1N80 G01 Z-.125 F18.N90 G41 D01 X0 Y0N100 G01 X2.0 F32.N110 Y1.5N120 X0.N130 Y0.N140 G40 X-.25 Y-.25N150 G00 Z1.N160 T2 M06N170 S4200 M03N180 G81 X.5 Y.5 Z-.6N190 X1.5N200 G80 G00 Z1.N210 M09 M05N220 M30( END ) ( CELL-04 O0042 )N10 G90 G94 G17 G20N20 G53 G00 Z0.N30 T1 M06N40 G54 X0 Y0 S6500 M03N50 G43 Z1. H01 M08N60 G00 X-.25 Y-.25N70 Z.1N80 G01 Z-.125 F18.N90 G41 D01 X0 Y0N100 G01 X2.0 F32.N110 Y1.5N120 X0.N130 Y0.N140 G40 X-.25 Y-.25N150 G00 Z1.N160 T2 M06N170 S4200 M03N180 G81 X.5 Y.5 Z-.6N190 X1.5N200 G80 G00 Z1.N210 M09 M05N220 M30( END )
// 03 - MATERIAL LAYER

Additive Manufacturing

Industrial polymer printing for short-run production parts, tooling, jigs, and end-use components. Dual platform: high-temp engineering grade and high-throughput prosumer.

// IDEX · INDUSTRIAL

VisionMiner 22IDEX

Build Volume450 × 450 × 600 mm
Hotend Temp500°C
Chamber Temp120°C
MaterialsPEEK · PEKK · ULTEM

Independent dual extrusion. Engineering polymers for aerospace, defense, and harsh-environment end-use parts.

// CORE ONE · PROSUMER

Prusa CORE One

Build Volume250 × 220 × 270 mm
Hotend Temp300°C
Chamber Temp55°C ambient
MaterialsPETG · ASA · NYLON · PC

CoreXY workhorse for jigs, fixtures, prototypes, and short-run shop floor production.

PEEK
High-temp aerospace & medical implants. Continuous 250°C+ service.
PEKK
Defense / FAA-rated. Flame retardant, low smoke, ESD-safe variants.
ULTEM 9085
FST-compliant. Aircraft interior panels, ducting, brackets.
NYLON CF
Carbon-fiber filled. Tooling, end-of-arm tools, drone arms.
PC-ABS
Tough impact-resistant. Enclosures, housings, fixtures.
TPU
Flexible elastomer. Gaskets, vibration dampers, soft grips.
// 04 - ON-SITE LAYER

On-Site Engineering

Boots-on-the-floor services. Six core service lines available as scoped projects or as part of a deployed engineering cell.

CNC Optimization

Cycle time reduction, fixturing redesign, toolpath review. Typical 18–40% throughput gain per cell on first pass.

Robot Commissioning

UR / FANUC / KUKA install, calibration, end-effector design, safety zoning, and full PLC integration to existing machinery.

Vision Systems

Cognex / Keyence / custom OpenCV pipelines. Inspection, defect detection, bin-picking, OCR, dimensional verification.

Predictive Maintenance

Sensor fusion + ML on vibration, current, temperature streams. Catch spindle bearing failure before it kills your shop.

SCADA & OEE

Real-time machine telemetry, dashboards, downtime tracking. Ignition, OPC-UA, MQTT - integrated into your stack.

Contract Staffing

Engineer network across central Texas, Montana, and Nebraska - software, controls, mechanical, electrical. Clearance-eligible vetted US citizens ONLY. Flex headcount without the W-2 overhead.

Where We Operate & How To Contact Us

Operations

Primary shop in Rapid City, South Dakota - CNC bay, robot integration cell, additive lab, electronics bench. Engineer talent network across central Texas, Montana, and Nebraska for flexible contract engagement. Cleared work handled in-house. We only employ well-vetted, highly experienced US citizens that have, have had, or can obtain a clearance.

EMAIL
shawsshank_engineering@protonmail.com
PHONE
970-398-0992
RESPONSE
< 4 business hours
RAPID CITY 44.0805° N · 103.2310° W  ·  CENTRAL TX 30.27° N · 97.74° W  ·  MT  ·  NE