Past
What got built. What broke. What that taught us.
PRESION Catch Can — 5 Generations
Complete · In Production
Started as a vacuum-holding problem nobody had solved in PA12 CF at this geometry. Third generation failed on infill. The failure forced the breakthrough — overextrusion sealing, microporosity elimination, print-in-place barb geometry. Five hardware generations. Now ships.
ATOMIZER WMI Nozzle — 9 Generations
Complete · Pending Revision
Pump-free water methanol injection via choked flow. The question was whether tank pressure alone could drive atomization at useful velocities. It can. Nine generations of internal geometry refinement. Currently under revision — PPA failing under hose clamp compression and heat creep. PA12 CF next.
Raycasting Aerodynamic Solver
Validated · Internal Use
Custom CFD approximation using ray-cast geometry to derive drag coefficients, downforce estimates, and surface pressure heatmaps from STL files. Built because commercial CFD tools were inaccessible, not because the math was simple.
Present
What's on the bench right now.
F150 Pushrod Suspension — Post-Runner Build
Active · Damper Rebuild Phase
Dual tandem damper, pushrod-actuated rear suspension on a 2005 F150. Adjustable motion ratios. Laser-cut PA12 CF composite rockers with bronze bushings. Built in four months on a $500 BOM. Validates the manufacturing method and the design philosophy before either gets applied to the UF-1. One damper blew on output — currently being rebuilt with in-house printed valve blocks.
In-House Rebuildable Damper
Active · Design Phase
Born from the F150 build. A fully rebuildable monotube damper with a 3D printed flow-control valve block replacing a traditional shim stack. The geometry is the valving curve — adjustable by reprinting, not by sourcing. Donor bodies from the build. Matched pairs for tandem applications.
Future
Where this is going.
UF-1 — American Hypercar
Theoretical · Active Development
The reason this all started. A ground-up hypercar designed around driver experience, not economies of scale. DOM tube frame. In-house axial flux motors. A 2-stroke V8 with blow-diffuser scavenging, pulsejet assist, and compressed air supercharging. 3D printed carbon fiber and fiberglass body panels over printed molds. The F150 is the first proof of method. The UF-1 is the destination.
Expanded Manufacturing
Pending · Post-Revenue
Proper shop space. Carbon fiber layup capability over printed molds. DOM frame fabrication. The manufacturing method is already defined — what's missing is the space to run it at scale.
Engineering Sample Room
Pending · Waiting for Shop Walls
Pedestals. Every part that failed and taught something. Every part that wasn't supposed to work and did. The third-gen catch can that broke on vacuum. The PETG shims that outlasted the theory. The rocker that cracked so we knew exactly where the limit was. These aren't the parts that build cars. These are the parts that build engineers.
In The Field
The post-runner. Proof of method.
Four months. $500. A pushrod suspension system that doesn't exist anywhere else at this price point on this platform. The red rocker is PA12 CF. The dampers are tandem. The geometry is adjustable. It works.
The industry optimizes for the wrong variable. Smooth is not fast. Fast is fast.
Sanchez Labs exists because the things worth building are usually the things nobody has a business case for. Every product here started as a problem that wasn't worth solving — until someone decided it was.
This is documented publicly because the process is the point. The failures are data. The iterations are the work. If you want to understand what this is, read the build logs.
Read the build logs →GET IN TOUCH
For R&D inquiries, collaboration, or anything else that doesn't fit a form.