Hill Engineering
Hill Engineering LLC is a Rancho Cordova, California–based engineering services firm that provides accredited residual stress measurement, fatigue analysis, and proprietary software (DART, ERS-Toolbox, BAMpF, Rapid Forge Design, IMx+) to aerospace, defense, power generation, and industrial customers worldwide.
- Company typePrivate
- Founded2005
- HeadquartersRancho Cordova, United States
- Headcount11–50
- GTM typeB2B
- OfferingServices
What Hill Engineering does
Hill Engineering LLC is a privately held, specialized engineering services and software company founded in 2005 and headquartered in Rancho Cordova, California, with a satellite office in Marriott-Slaterville (Layton), Utah. The firm provides residual stress measurement, mechanical design, material testing, structural integrity, and fatigue engineering services — offering nine major measurement techniques spanning near-surface methods (X-ray diffraction, hole drilling per ASTM E837, TrueSlot®, Barkhausen noise analysis, ring core) and bulk methods (contour method under license from Los Alamos National Laboratory, slitting method, deep hole drilling, neutron diffraction via Oak Ridge National Laboratory). Hill Engineering holds the only ISO/IEC 17025 accreditation worldwide for slitting method residual stress measurements.
The company monetizes through three revenue streams: (1) fee-for-service residual stress measurement, performed in its accredited laboratory or onsite at customer facilities, including a premium expedited service branded ExpressRS®; (2) one-time licenses for proprietary software products — DART™ (automated hole-drilling measurement), ERS-Toolbox® (eigenstrain-based residual stress prediction for shot peening, laser shock peening, and cold hole expansion), Rapid Forge Design® (closed-die forging automation), BAMpF® (multi-point fatigue crack growth analysis integrating with ESRD's StressCheck and AFGROW), and IMx+ (integrated maintenance data collection, co-developed with Fatigue Technology and NLign Analytics); and (3) engineering consulting including fatigue analysis, fatigue testing, machining distortion modeling, heat treatment modeling, and 3D scanning. Pricing is quote-based and not publicly disclosed.
Customers are concentrated in aerospace and defense (Lockheed Martin, US Air Force Research Laboratory, Rolls-Royce Corporation, Pratt & Whitney), with adjacent exposure in power generation, turbo-machinery, petrochemicals, and vehicles. Sales are conducted through direct enterprise field engagement supported by technical conferences (Residual Stress Technology Conference, AFGROW Users Workshop, SEM, ICRS), peer-reviewed publications, and a technical blog. The firm operates as a non-treatment provider, positioning itself as an independent and objective engineering advisor across the residual stress lifecycle.
Hill Engineering firmographics
Firmographics- Name
- Hill Engineering
- Legal name
- Hill Engineering LLC
- Website
- https://hill-engineering.com
- Company type
- Private
- Founded year
- 2005
- Operating status
- Operating
- Headcount range
- 11–50 employees
- Short description
- Hill Engineering LLC is a Rancho Cordova, California–based engineering services firm that provides accredited residual stress measurement, fatigue analysis, and proprietary software (DART, ERS-Toolbox, BAMpF, Rapid Forge Design, IMx+) to aerospace, defense, power generation, and industrial customers worldwide.
- Ownership category
- akta.pro rank
Hill Engineering industry classification
Industry- Product category
- Residual Stress Engineering and Measurement Services
- NAICS
- Testing Laboratories and Services (54138), Instrument Manufacturing for Measuring and Testing Electricity and Electrical Signals (334515)
- SIC
- Industrial Instruments For Measurement, Display, And Control (3823), Services-Testing Laboratories (8734)
- akta.pro primary industry
- Reliability, Safety & Risk Engineering (RAMS/PSM) Consulting (BPAHAIAK)
- akta.pro secondary industries
- Condition Monitoring & Reliability Services (Vibration/Oil Analysis/RCM) (IMAIACAL), Rotating Equipment Inspection & Vibration Diagnostics (Turbines, Compressors, Pumps) (EUAEAHAJ)
Keywords
Where Hill Engineering is headquartered
LocationHeadquarters
- HQ city
- Rancho Cordova
- HQ country
- United States
- HQ region
- North America
Offices2 records
Markets served
Hill Engineering business model
Business model- GTM type
- B2B
- Offering type
- Services
- Cost components
- Personnel, Technology or R&D, Operations, Infrastructure, Marketing or Sales
Revenue model
- Residual Stress Measurement Services: Hill Engineering provides fee-for-service residual stress measurements using their broad range of techniques including contour method, slitting, hole drilling, neutron diffraction, and others. Services are available in their laboratory or on-site at customer facilities.
- Product Sales (DART™, ERS-Toolbox®, Rapid Forge Design®, BAMpF®, IMx+): Hill Engineering sells proprietary products including the DART automated measurement system, ERS-Toolbox software, Rapid Forge Design software, BAMpF software, and IMx+ integrated maintenance system. Products are sold directly to customers.
- Engineering and Consulting Services: Hill Engineering provides engineering consulting services including fatigue analysis, fatigue life extension, fatigue testing, machining distortion modeling, heat treatment modeling, mechanical stress relief modeling, residual stress engineering, surface treatment engineering, strain gaging, and 3D scanning services.
Go-to-market motion2 records
Distribution channels4 records
Marketing channels12 records
Hill Engineering product offering
Product offeringCore offering
Hill Engineering provides residual stress measurement, mechanical design, and material testing services to engineers across aerospace, power generation, turbo-machinery, petrochemical, and vehicle industries. The company sells proprietary software and automated measurement hardware (DART™, ERS-Toolbox®, Rapid Forge Design®, BAMpF®, IMx+) and provides engineering consulting in fatigue analysis, fatigue life extension, surface treatment engineering, heat treatment modeling, machining distortion modeling, mechanical stress relief modeling, strain gaging, and 3D scanning. Services and products are delivered through an ISO/IEC 17025 accredited laboratory in Rancho Cordova, CA, on-site field measurement teams, and direct enterprise engagement.
Product overview
Hill Engineering offers a portfolio of specialized software products for residual stress measurement, analysis, and engineering applications. The core products include DART™ (automated near-surface residual stress measurement), ERS-Toolbox® (residual stress and distortion prediction software for surface treatment design), Rapid Forge Design® (automated forging design), BAMpF® (multi-point fatigue crack growth analysis), and IMx+ (automated maintenance data collection). These products are complemented by a comprehensive suite of residual stress measurement services (Contour Method, Slitting, Hole Drilling, X-ray Diffraction, Neutron Diffraction, Deep Hole Drilling, Ring Core, TrueSlot®, Barkhausen Noise Analysis) and engineering services (Fatigue Analysis, Fatigue Life Extension, Surface Treatment Engineering, Heat Treatment Modeling, Machining Distortion Modeling). The product portfolio forms an integrated ecosystem enabling customers to measure residual stress, predict manufacturing effects, optimize designs, and ensure quality control throughout product lifecycle.
Differentiator
Problem solved
Functional benefit
Brands
- DART™: Automated residual stress measurement system for near-surface stress measurements using hole drilling and TrueSlot® methods
- ERS-Toolbox®
- Rapid Forge Design®
- BAMpF®
- ExpressRS®
- IMx+
Products and services
- DART™ Automated, industry-leading system for performing near-surface residual stress measurements using hole drilling, TrueSlot®, and Ring Core methods per ASTM E837. Features intuitive user interface, automated measurement execution and residual stress calculation, with measurements completing in less than 60 minutes and 50%+ improvement in measurement repeatability versus other hole drilling equipment. Sold to enterprise customers including aerospace manufacturers.
- ERS-Toolbox® Computational design tool that predicts the residual stress and distortion caused by processes providing compressive residual stress, including shot peening, laser shock peening, and cold hole expansion. Based on eigenstrain methodology, enables virtual trials of treatment processes and rapid design optimization. Compatible with Ansys and Abaqus finite element modeling tools. Developed over more than a decade through government and private industry collaboration.
- Rapid Forge Design® Automated tool for fast and reliable design of 2-piece, closed-die impression forgings. Reads final part geometry and automatically designs a forging according to accepted industry guidelines and user-defined parameters, outputting 3D geometry and useful forging statistics. Generates forging designs in minutes to accelerate forging engineering workflows.
- BAMpF® (Broad Application for Multi-Point Fatigue) Enables fatigue crack growth analysis of parts with non-standard geometry, loading, and residual stress conditions through multi-point fracture mechanics (MPFM). Uses StressCheck p-element finite element analysis for fast 3D analysis with natural fatigue crack shape progression. Interfaces with AFGROW for fatigue life assessment and StressCheck for stress intensity factor calculation.
- IMx+ (Integrated Maintenance System) Automated data collection system for critical maintenance processes such as cold expansion of fastener holes and nondestructive inspections in aerospace applications. Assigns data to the actual spatial location of executed tasks to ensure correct maintenance is performed at the correct location. Developed in partnership with Fatigue Technology and NLign Analytics, with integration to DigitalEx, NCheck, NLign, NORTEC 600, and iGPS spatial tracking.
- Residual Stress Measurement Services Fee-for-service residual stress measurements across a broad range of techniques — contour method, slitting, hole drilling, neutron diffraction, X-ray diffraction, deep hole drilling, ring core, TrueSlot®, and Barkhausen noise analysis — delivered in Hill Engineering's ISO/IEC 17025 accredited laboratory in Rancho Cordova, CA or on-site at customer facilities for large, delicate, or untransportable components. Serves aerospace OEMs, power generation, turbo-machinery, petrochemical, and vehicle manufacturers.
- Engineering and Consulting Services Engineering consulting across fatigue analysis, fatigue life extension, fatigue testing, machining distortion modeling, heat treatment modeling, mechanical stress relief modeling, residual stress engineering, surface treatment engineering, strain gaging, and 3D scanning services. Supports aerospace, defense, power generation, turbo-machinery, petrochemical, and ground vehicle customers with structural integrity and manufacturing process decisions.
- ExpressRS® Expedited Residual Stress Measurement Service Expedited residual stress measurement service with priority laboratory queue, delivering typically less than one week, with next-day service available in select cases. Available across contour, slitting, hole drilling, TrueSlot®, ring core, and deep hole drilling techniques to support customers with tighter deadlines.
Quantifiable outcome
- DART™ provides 50%+ improvement in measurement repeatability relative to other hole drilling test equipment
- +3 more outcomes
Companies that use Hill Engineering
Customer profileNamed customers7 records
Segments5 records
Ideal customer profiles3 records
Hill Engineering technology and API
TechnologyTechnology focussed Yes
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Integration9 records
Feature16 records
Hill Engineering partnerships and signals
Strategic signalPartnerships
Eight partnerships are on record, tiered core and minor.
- Fatigue TechnologycoreFatigue Technology is a key partner in the development of the IMx+ Integrated Maintenance System. Their DigitalEx system is a component of the IMx+ system. Fatigue Technology specializes in cold expansion of fastener holes and related aerospace maintenance technologies.
- NLign AnalyticscoreNLign Analytics partnered with Hill Engineering to develop the IMx+ Integrated Maintenance System. NLign provides NCheck and NLign software for the user interface of the system, which integrates with spatial tracking (iGPS) and NDI systems.
- Oak Ridge National Laboratory (ORNL)coreHill Engineering works with beamline staff at Oak Ridge National Laboratory's High-Flux Isotope Reactor (HFIR) to plan and execute neutron diffraction residual stress measurements. This partnership provides access to specialized neutron diffraction capabilities for bulk residual stress mapping.
- Pratt & WhitneycoreHill Engineering performed residual stress measurements on nickel and aluminum specimens to support Pratt & Whitney's Materials & Processes Engineering group. Results were presented by Pratt & Whitney at ICRS 12 conference in Detroit, MI (October 2025).
- Worcester Polytechnic Institute Integrative Materials Design CenterminorHill Engineering collaborated with WPI's Integrative Materials Design Center to publish research on fatigue crack growth in aluminum friction stir welds in the International Journal of Fatigue. The collaboration informs design decisions for improved fatigue performance.
- Los Alamos National LaboratorycoreLos Alamos National Laboratory invented the Contour Method circa 2000 and patented it. Hill Engineering has been active in the development of the Contour Method since 2000 and operates under license from LANL to use the method commercially. Mike Prime, inventor of the contour method, is honored in Hill Engineering's Prime Room.
- ESRD (StressCheck)coreESRD's StressCheck p-element finite element software is integrated into Hill Engineering's BAMpF software for fatigue crack growth analysis. BAMpF queries stress intensity factors specific to part geometry and loading through the StressCheck interface.
- AFGROWcoreAFGROW (a leading fatigue life assessment tool) is integrated into Hill Engineering's BAMpF software. BAMpF provides necessary inputs to AFGROW for fatigue crack growth analysis and stores expected fatigue crack growth for given cycle counts.
Scale indicators3 records
Recent moves9 records
Expansion highlights5 records
Hill Engineering competitors and assessment
Company assessmentBroad incumbents
- Bruker Corporation: Manufacturer of X-ray diffraction and analytical instrumentation, including residual stress measurement systems. Hill Engineering uses Bruker-style XRD equipment; Bruker's D8 family competes with custom lab setups for residual stress characterization.
- Intertek: Global TIC giant offering aerospace materials testing, structural integrity, and quality assurance services. Provides broader testing portfolio at higher scale but lacks Hill's residual-stress specialization.
- Element Materials Technology: Global testing, inspection, and certification (TIC) company with extensive materials testing labs. Provides fatigue, fracture, and mechanical testing at much greater scale; a potential partner or acquirer rather than a niche direct competitor.
- Applus+ (Applus Laboratories): Spain-based global TIC group with aerospace materials and structural testing capabilities. Competes indirectly for aerospace testing budgets and could absorb residual stress work as part of broader engagements.
Direct peers
- StressTech Group (Stresstech Oy): Finnish-headquartered specialist in Barkhausen noise analysis and X-ray diffraction for residual stress measurement. Provides both instruments (ScanStress, RollScan) and measurement services, overlapping directly with Hill's Barkhausen and XRD offerings.
- Lambda Technologies: US-based provider of residual stress measurement services using X-ray diffraction, contour method, and slitting, plus cold spray and shot peening services. Directly competes with Hill Engineering in aerospace residual stress characterization.
- Sint Technology: Italian firm specializing in contour method residual stress measurement and consulting, serving European aerospace and energy customers. Closest international peer in the contour method niche.
- Proto Manufacturing: US-based laboratory specializing in X-ray diffraction residual stress measurement services for aerospace, automotive, and industrial customers. A direct competitor in the XRD residual stress service market.
Others
- Fatigue Technology Inc. US provider of cold expansion services for fastener holes and a development partner on Hill's IMx+ Integrated Maintenance System. Operates in the adjacent aerospace structural integrity space rather than competing directly on residual stress measurement.
- Olympus / Evident Industrial: Manufacturer of industrial NDT equipment (ultrasonic, eddy current, phased array). Provides complementary inspection tools used in structural integrity programs but does not specialize in residual stress measurement.
Market position
Strengths5 records
Weaknesses5 records
Competitive moat5 records
Key risks5 records
Key highlights6 records
Customer concentration
Hill Engineering social profiles
Digital presenceHill Engineering compliance and trust
Trust signalCompliance1 record
Hill Engineering financial estimates
Financial estimateRevenue estimate
Valuation estimate
Hill Engineering leadership team
Management profileNumber of profiles
Profiles5 records
Hill Engineering funding detail
Funding detailFunding overview
Funding rounds
Investors
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Hill Engineering M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Hill Engineering
What does Hill Engineering do?
Hill Engineering provides residual stress measurement, mechanical design, and material testing services to engineers across aerospace, power generation, turbo-machinery, petrochemical, and vehicle industries. The company sells proprietary software and automated measurement hardware (DART™, ERS-Toolbox®, Rapid Forge Design®, BAMpF®, IMx+) and provides engineering consulting in fatigue analysis, fatigue life extension, surface treatment engineering, heat treatment modeling, machining distortion modeling, mechanical stress relief modeling, strain gaging, and 3D scanning. Services and products are delivered through an ISO/IEC 17025 accredited laboratory in Rancho Cordova, CA, on-site field measurement teams, and direct enterprise engagement.
Is Hill Engineering a public or private company?
Hill Engineering is a private company. It is classified as founder individual operated bootstrapped and is currently operating.
When was Hill Engineering founded?
Hill Engineering was founded in 2005. It employs 11 to 50 people.
Where is Hill Engineering based?
Hill Engineering is headquartered in Rancho Cordova, United States, in the North America region.
How does Hill Engineering make money?
Three revenue lines are on record. Residual Stress Measurement Services are the primary driver. The others are product Sales (DART™, ERS-Toolbox®, Rapid Forge Design®, BAMpF®, IMx+) and engineering and Consulting Services.
Who are Hill Engineering's main competitors?
Broad incumbents on record are Bruker Corporation, Intertek, Element Materials Technology and Applus+ (Applus Laboratories). Direct peers are StressTech Group (Stresstech Oy), Lambda Technologies, Sint Technology and Proto Manufacturing. Others are Fatigue Technology Inc. and Olympus / Evident Industrial.
Does Hill Engineering have an API?
No public API is recorded for Hill Engineering.
What industry is Hill Engineering in?
Hill Engineering's product category is Residual Stress Engineering and Measurement Services. Its primary akta.pro industry code is BPAHAIAK, Reliability, Safety & Risk Engineering (RAMS/PSM) Consulting, with a secondary code of IMAIACAL, Condition Monitoring & Reliability Services (Vibration/Oil Analysis/RCM). Its NAICS code is 54138 and its SIC code is 3823.