Specialist AI agents for manufacturing

From idea to production — in days, not months.

A team of physics-trained AI agents balancing quality, costs, and emissions — across every manufacturing phase.

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Concept-phase 3D render of an injection mold cavity — streamlined shell with conformal cooling channels (white tubes) and a thermal gradient indicating the hotspot region.

Physics · fill

Zephyra● online

Customer sent this part. Quote by tomorrow — 50k pcs/yr. 3 options with quality risks flagged.

✓ 3 options · ABS, P20 steel

cavitiesinvestmentpiecepaybackROI (3yr)

1€15,724€0.585——

2€24,448€0.46817.9 mo101%

4€41,897€0.427[tbd][tbd]

⚠Wall 1.04 mm — 1-gate fill needs 470–870 bar

→2-gate drops to 4–7 bar, fill 0.35 s

⚠47% of part prone to heat accumulation (17 °C ΔT)

→conformal cooling drops to 15 °C, cycle 2.6 s

→ Generate quote pack

Ask about your results…↑

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Concept design

Catch manufacturability issues before you commit — in minutes, not weeks.

Will it be made? Which material? Which technology? How much? Four answers on your CAD, before a euro is committed.

Will it be made?

Feasibility verdict + risk flags

Which material?

Ranked shortlist + trade-offs

Which technology?

Process recommendation (IM · DC · TF · AM)

How much?

Investment, piece cost, payback, ROI

drag to rotate

2.34M configurations · 5 shortlisted · 3 recommended

Geometry × material × process × economics, evaluated against quality, cost, cycle, CO₂.

Traditional DFM review

2–3 weeks · ~€8k

Zephyra

minutes · on your CAD

See it on your part

Tooling design

Get the mold right the first time — before you cut steel.

Cooling layout and gate positions optimization. Designed and optimized on your part, before tooling is committed.

Injection

Optimized layout

+ cycle target

Gates & runners

Position, count, balance

+ fill physics

A TPMS lattice cooling channel network generated by the Process agent — an organic, interconnected structure that can only be manufactured additively as a 3D-printed steel insert. — optimized vs conventional · 30s vs 90s · ΔT 9 °C vs 17 °C

Trade-off based on thousands of configurations, then optimized for your needs.

Traditional mold design

4–8 weeks · 1–2 trial molds

Zephyra

hours · zero trials before cut

See it on your part

Production optimization

Cut your energy bill in half — without changing the mold.

Process parameters and cooling, optimized on the press you already have. Measured against quality, validated for export.

Energy

−20% to −50%

measured

CO₂

Lower per-piece footprint

CBAM-ready reporting

Cycle

Faster, same quality

Validated & exportable

Moldflow, Ansys, Abaqus

handoff ready

Live KPI dashboard — time-series plots of cost, emissions, machine hours, and water usage, baseline vs optimized. — Baseline 0.42 kWh/pc → optimized 0.21 kWh/pc

At 50k pcs/yr: 10,500 kWh saved · 4.2 t CO₂ avoided · €1,800/yr.

Manual process tuning

weeks · trial and error

Zephyra

hours · measured · validated

See it on your part

Who it’s for

Three teams. Same loop.

Respond to RFQs in hours, not weeks.

Quote with confidence the same day. Feasibility + cost estimate + cooling time before the lead goes cold.

For toolshops where quote turnaround wins the deal.

Catch design issues before the shop floor.

Wall thickness, draft angles, filling risks — caught in minutes. No more €40k tooling write-offs from a missed undercut.

For OEM and tier-1 design engineers.

Cut emissions on every part.

Every design iteration tracks CO₂, water, and energy. When customers ask for sustainability data, you have it ready.

For suppliers whose customers ask about carbon.

Customer outcomes

From their factory floor.

Medical

Eltek

48 h 4 h Analysis time

PMMA medical-grade. 0.01 mm geometric tolerances. Channels Ø 0.40 ±0.02 mm. Single injection point required.

“Zephyra lets us explore options at a speed that matches our mission — getting medical devices to patients in weeks, not months.”

— Massimo Zanin, R&D, Eltek

4 million simulations explored, in 5 minutes.
1,000 feasible solutions auto-filtered for quality, cost, emissions, and homologation.
3 final candidates handed off to Eltek's tooling lead for Moldflow validation.

Automotive supplier

Honestamp

90 s 30 s Cycle time per shot

Sub-0.1 mm tolerances. SLM-printed cooling system. Mold went into production with no pilot run.

“Our strong points are manufacturing flexibility and speed to reply to enterprises' stringent needs. Zephyra provides some tools that align on our vision.”

— Simone Lingeri, CEO

−66% cycle time per shot.
Press capacity more than doubled — same hardware, same shift.
Tolerances moved from borderline to fully compliant (< 0.1 mm).

Ready when you are

Bring a part. Get an answer.

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