Southways | Design; Development; Project Management

The Pedigree of Southways

Southways isn’t a hobbyist 3D-print shop or a generic design agency. Founded in 1996 by Ken Nunn, a toolmaker by trade with decades of elite industrial design & advanced manufacturing experience, we approach product development with discipline & precision.

Following years of concurrent development, Southways commenced full-time engineering consulting operations in 2009. Our mastery of traditional plastics technology is uniquely paired with high-performance automotive development, including an extensive history with Ken serving as the General Manager/Technical Director for both Harrop Engineering in Australia and Magnuson Superchargers in the USA.

Today, we leverage that exact OEM-level rigor to design, simulate, and manage complex manufacturing workflows for niche clients who require flawless real-world execution.

Established 1996

Rooted in traditional precision toolmaking and machining. We design with an intuitive understanding of materials, structural integrity, tooling, and manufacturing.

Consulting Since 2009

Over a decade and a half of dedicated, full-time technical consulting delivering specialized engineering solutions directly to independent clients.

Forced Induction DNA

Ken has authored patents for supercharger technology & Southways has consulted directly with Eaton Corporation developing new induction technologies. Decades of award-winning expertise in complex packaging, drive systems, and volumetric efficiency.

Advanced Composites

Extensive experience in polymer behavior, optimizing high-strength structural engineering utilizing glass and carbon-filled mediums, including tooling & post-processing operations.

Core Technical Capabilities

In-House Scanning & 3D Printing

Accelerated prototyping and reverse engineering backed by robust, in-house technical manufacturing capabilities to shrink lead times from days to hours.

High-accuracy 3D scanning to capture physical spaces and reverse-engineer complex mechanical constraints.
Three in-house specialised 3D printers, including a large-format 600mm cube IDEX system for major industrial components.
Specialised processing of advanced structural polymers, focusing primarily on high-durability Carbon and Glass-Filled polymers.

CAD/CAM & FEA Simulation & Validation

Advanced 3D modelling integrated with FEA. We validate that a design functions optimally before any raw material is cut or printed.

High-fidelity parametric modeling for sophisticated individual components & sub-assemblies.
Finite Element Analysis (FEA) to simulate air, liquid & polymer flow; isolate mechanical stresses; and evaluate structural displacement.
Creating detailed documentation to ensure true-to-spec verification via strict physical tolerance compliance.

Forced Induction & Composites

World-class packaging layout for niche induction environments. We leverage a proven high-performance pedigree to build robust structural components with optimal charge-air pathways.

Bespoke supercharger drive line integration, alignment and tension configuration.
High-efficiency induction plenums, intake path balancing, with optimum thermal control.
Complete system project management from concept layouts to track-validated end products.

The Project Vault

Automotive Solutions

Click to explore complete forced induction hardware and other high performance automotive components.

Consumer & Industrial Projects

Click to explore complex mechanical mechanisms and niche project solutions.

Automotive Engineering Gallery

Over The Radiator Cold Air Induction Assembly (OTRCAI)

For VE-VF V8 Commodore, view from front left. Significant FEA for optimised flow & structural integrity.

Over The Radiator Cold Air Induction Assembly

For VE-VF V8 Commodore, view from rear left.

Over The Radiator Cold Air Induction Housing

Injection moulded in PA6-GF20. For VE-VF V8 Commodore, view from front right.

Over The Radiator Cold Air Induction Housing

Injection moulded in PA6-GF20. For VE-VF V8 Commodore, view from front left.

Over The Radiator Cold Air Induction Housing

Injection moulded in PA6-GF20. For VE-VF V8 Commodore, view from rear left.

Over The Radiator Cold Air Induction Assembly

Naturally Aspirated VF V6 Commodore, view from rear.

Over The Radiator Cold Air Induction Assembly

Naturally Aspirated VF V6 Commodore, view from front.

Cold Air Induction Assembly

2024 Ford Ranger components

Cold Air Induction Assembly

2024 Ford Ranger components

Cold Air Induction Assembly

2024 Ford Ranger components

Facia Panels for OTRCAI

Engine compartment aesthetic panels.

Facia Panels for OTRCAI

Engine compartment aesthetic panels.

Throttle Body Adaptor Assembly for Magnuson Supercharger

Places Cable-pull 108mm Throttle Body at compound angles. Flow optimised with FEA. 3D printed in PA6-GF30.

Throttle Body Adaptor Assembly for Magnuson Supercharger

Places Cable-pull 108mm Throttle Body at compound angles. Includes hidden nuts & OEM vacuum ports.

Throttle Body Adaptor Sub-Assembly for Magnuson Supercharger

Places Cable-pull 108mm Throttle Body at compound angles. Includes hidden nuts & captive internal cap-screw.

Throttle Body Adaptor Sub-Assembly for Magnuson Supercharger

Places Cable-pull 108mm Throttle Body at compound angles. Utilising a TPU 3D-printed gasket & OEM vacuum fittings.

108mm Bore Fly By Wire Thottle Body

High-performance electronic throttle body for GM LS3-based vehicles.

108mm Bore Fly By Wire Thottle Body

High-performance electronic throttle body for GM LS3-based vehicles.

LS3 Manifold Upgraded for 108mm Throttle Body

Injection moulded adaptor inserted into CNC machined OEM manifold with 108mm throttle body.

Magnuson GM Heartbeat Supercharger

This design changed the supercharger industry. FEA optimised with modular components.

Magnuson Heartbeat Supercharger GM Engine Kit

Chev Camaro engine kit.

Magnuson Heartbeat Supercharger GM Engine Kit

Holden VE-VF Commodore & Pontiac G8 engine kit.

Magnuson Heartbeat Supercharger

Complete Assembly Cross-Section.

Magnuson Hammer Supercharger for AMG M156

Designed & manufactured in Australia for the 2008-2014 Mercedes AMG C63 & other M156 variants.

Magnuson Hammer Supercharger for AMG M156

Utilises AMG OEM fittings, sensors, throttle bodies and the Eaton TVS2300 rotating group.

Magnuson Hammer Supercharger for AMG M156

Direct bolt-up with no permanent changes to the vehicle.

Magnuson Sledge-Hammer Supercharger for AMG C63

Independant 8PK drive belt upgrade for the C63.

Sledge-Hammer Kit for the Magnuson Hammer Supercharger

Independant 8PK drive belt upgrade for the C63.

Sledge-Hammer Kit for the Magnuson Hammer Supercharger

Massive overdrive pulleys without belt slip.

Magnuson Supercharger for the Audi RS4

Visualising structural integrity and air delivery dynamics.

Magnuson Supercharger for the Jeep 3.6

Developing layouts for tight configurations & utilising OEM components.

Upgraded GM LSA Supercharger Drive Cover

FEA optimised flow with dramatic performance improvements.

Upgraded GM LSA Supercharger Drive Cover

Structual rigidity validated with FEA.

Upgraded GM LSA Supercharger Drive Cover

A complex casting & machining challenge.

Upgraded GM LSA Supercharger Drive Cover

Direct bolt-on utilising OEM fittings etc.

Upgraded GM LSA Supercharger Drive Cover

Options for 112mm throttle body & pulley variants.

VE-VF Commodore Charge Air Coolant (CAC) Manifold Assembly for Magnuson Heartbeat

High-performance coolant manifold utilising quick-connect fittings.

VE-VF Commodore Charge Air Coolant (CAC) Manifold Casting

Tightly constrained geometry with significant casting challenges.

Front End Supercharger Drive (FESD) Tensioner Bracket for LSA

FEA validated billet tensioner bracket for LSA FESD.

Front End Supercharger Drive (FESD) Tensioner Bracket for LSA

Optimised to eliminate belt misalignment and displacement.

Front End Supercharger Drive (FESD) Tensioner Bracket for LSA

Minimised mass by FEA simulation of material variants.

Monoblock Forged Wheel for Cadillac CTS-V

Integrating styling aesthetics with robust performance.

Monoblock Forged Wheel for Cadillac CTS-V

Spoke architecture load analysis under severe cornering load via FEA.

V8Supercar Tuned Length Exhaust Headers

Optimized layout within tight space envelope.

V8Supercar Tuned Length Exhaust Headers

Diameters & lengths within very tight tolerances.

Consumer & Industrial Products Gallery

Electric Skateboard - Longboard

Design & project management of the mechanical drive system, electronic enclosures, wheels, etc. Production of marketing animations.

Electric Skateboard - Shipping & Carry Case

Nested components within the casing for each of the three skateboard variants.

Skateboards Display Stand Concept

Composite mouldings.

Skateboards Display Stand Concept

Laser-cut panels for on-site assembly.

Skateboard Wheels

Evaluating load centers across tracking layouts.

Skateboard Wheels

Evaluating load centers across tracking layouts.

All-Terrain Skateboard Wheels

Overmoulding of TPU for grip & dampening.

All-Terrain Skateboard Wheels

Overmoulding of TPU for grip & dampening.

Electrical Wire Looms

"Push to Seat" connectors and colour coding with flexible conduit.

Electrical Wire Looms

"Push to Seat" connectors and colour coding.

Point Of Sale Products

Pushbike & skateboard helmet merchandising display rack.

Point Of Sale Products

Pushbike & skateboard helmet merchandising display rack.

Point Of Sale Products

Pushbike & skateboard helmet merchandising display rack.

Quick-Release Buckle Assembly

Device for instant release from personal protection garments.

Quick-Release Trigger Assembly

Device for instant release from personal protection garments.

Side-arm Holster Lock Assembly

Safety release mechanisim utilising high strength polymers.

Side-arm Holster Retention Assembly

Safety release mechanisim utilising high strength & flexible polymers.