Engineering — NIRO Corp Hardware Release Package

What's in the release package

For each of the two drone hardware programs, the following artefacts exist in controlled form today:

Stamped mechanical drawings with GD&T. 9 SkyWrite drawings (SW-001 through SW-014) and 9 Drone-Satellite drawings (DS-001 through DS-006C). ISO/ASME position, concentricity, perpendicularity, and flatness tolerances. H7 fits for precision alignment. Surface-finish tiers at Ra 0.4–0.8 / 1.6 / 3.2 µm. Material standards referenced (ASTM B221, A240, B166/B168), heat-treatment specs called out, protective finishes specified (MIL-A-8625 Type II anodize, passivation per ASTM A380).
Consolidated BOMs. Two sheets, one per product, with a shared 19-column schema: part ID, description, qty, primary vendor, primary P/N, primary link, unit price at qty 1 / 10 / 100 / 1000, lead time, MOQ, country of origin, alternate vendor, alternate P/N, alternate link, source note. SkyWrite BOM: 44 rows. Drone Satellite BOM: 38 rows.
Harness-and-wiring release. For SkyWrite: J1–J10 connector pinouts, H1-PWR-MAIN through H10-TC-SPI harness cut lengths, crimp-tool class by termination family, pull-test acceptance criteria, fuse hierarchy (F1 25 A heater + F2 7.5 A aux + 240 °C thermal fuse), text power-rail diagram. For Drone Satellite: full wiring release with pinouts.
FMEA. Per-subsystem failure-mode and effects analysis covering heater, fluid, pump, docking, and relay subsystems.
Deterministic simulation suites. Nine Python simulators for SkyWrite alone: color_sim (purge effectiveness), camera_sim (capture framing), refresh_sim (swarm + refresh), qr_sim (QR readability), swarm_sim, sync_sim (dual-drone sync), letter_harness (letter-level SIL), run_monte_carlo (mission-level MC), endurance_soak (50,000-cycle real-orchestrator soak test).
IKEA-style assembly manuals. Step-by-step procedures with torque specs, verification criteria, PPE requirements, hot-work permits, electrical safety procedures, acceptance testing, test points, measurement procedures, and calibration requirements. SkyWrite assembly manual alone is 2,900+ lines of released procedure.
Thermal and structural analysis. Released weight-budget, thermal-analysis, and structural-analysis documents.
Regulatory compliance matrix and roadmap. FAA, FCC, and CE tracks identified; tethered-satellite Part-107 fast path documented for Drone Satellite.

Two rounds of independent master audit

The program went through a two-round independent audit in April 2026 covering simulation integrity, drawing release, BOM consolidation, wiring completeness, and thermal-runaway analysis. Round 1 identified 17 P0 items. Round 2 closed 11 outright, 4 with documented caveats, and flagged 2 as bench-data-required.

Importantly, we did not paper over the residuals. The honest status per the closeout document:

Item	Status
Sim integrity (color, camera, endurance soak)	Closed. Rigging factors removed from `color_sim` and `camera_sim`; live `endurance_soak` runs the real `simulate_mission()` path, 50,000 cycles, 0 errors.
Drone-Sat pursuit-controller timing bug	Closed at doc level; pending runnable rerun.
Fluid-line geometry reconciliation	Closed — heater bore is Ø2.5 mm × 380 mm → 1.87 mL; feed-tubing inner-diameter / length to be pinned down in a released spec.
Heater >800 °C duty cycle envelope	Test-card structure present; measured bench data required before we publish a defensible envelope.
Wireless-charging alignment / efficiency data	Bench data required before we publish figures.
GD&T drawings across P0 parts	Closed — 15+ stamped drawings released 2026-04-07.
Consolidated BOMs (no mixing)	Closed — two separate sheets in `NIRO_BOM_Master.xlsx`.
Wiring release (one per product)	Closed — SkyWrite and Drone-Sat wiring releases live.

What we will and will not quote

We won't requote headline simulation pass-rate numbers that the closeout document retracted. Specifically:

Previous public claim: "100% simulation pass rate across all scenarios." Post-audit honest rates: color_sim 68.9% at ≥95% condition threshold; camera_sim 6.2% at the physics-only threshold. Those are real physical issues (purge-duration margin, camera frame-fill at typical capture geometry) that a hardware or firmware change has to close before we quote them again. We'd rather disclose that than repeat a number we can no longer defend.

Sims that held up through the honest rerun, and that we'll quote: refresh_sim (100%, 600/600 MC trials), qr_sim (100% across wind regimes), swarm_sim (100%, 45 conditions × 100 iterations), sync_sim (100%, 48/48), letter_harness (30 pass / 0 fail), run_monte_carlo (100%, 5,000/5,000 mission trials), endurance_soak (50,000 cycles real orchestrator, 0 errors, 0.145 MB memory drift, 1.28× timing degradation against a 2× threshold).

Manufacturing

PCBWay — CNC 6061-T6 aluminum, sheet-metal 304 SS, laser-cut PMMA, 3D-print TPU 95A and PETG. 8 parts in active cart from April 10; 10 more queued for standalone-upload per the parts-registry separation rule.
Xometry — precision CNC for Inconel 600 heater core (SW-014: helical bore Ø2.5 ± 0.05 mm × 9.5 turns, cartridge bores Ø6.05 H7, Ra 1.6 µm internal, 800 °C operating temperature).
Material corrections vs the legacy 569-page PDF (now retired): SW-002 hot liner corrected to 304 SS; DS-006B/C hook-and-receiver corrected to 440C SS at HRC 50–55; DS-001 carrier fixture corrected to 6061-T6; SW-014 heater core corrected to Inconel 600.

Intellectual property

US Patent 12,252,279 B1 — Drone Satellite (granted). System-level architecture patent covering autonomous airborne relay.
Patent pending — SkyWrite heater-core geometry and aerial-messaging method.
Continuation strategy — captured internally; available under NDA.

For reviewers

The full engineering package (stamped drawings, BOMs, wiring, FMEA, sim results, assembly manuals, audit closeout) is available under NDA for reviewers, investors, partners, and licensees. Start with contact.

SkyWrite product page · Drone Satellite product page · About NIRO.