Prototyping & Design For Manufacturing

Material Type – There are countless options when choosing sheet materials and we have vast experience in working with a large variety of them. You tell us your desired specifications, and we will choose the most appropriate material for your project. Important material factors we address include:

  • Strength
  • Grade & quality
  • Indoor or outdoor application
  • The material’s ability to support hardware
  • Durability over time
  • Surface finish
  • Flatness and material stability
  • Finishing considerations

Material Form and Availability – Materials come in many shapes and sizes.
Some materials are only available in dimensions that require additional workholding considerations. We will employ various methods to accommodate these situations if the given material is exactly what you want. In other cases, we will offer different options that meet your specifications as closely as possible. In addition to this, we will communicate with the material suppliers to ensure that the final material choice is available from a reputable manufacturer and foreseeable shortages or lack of availability will be mitigated. We will also take considerations within design and layout to make the most efficient usage of material. Based on these considerations, you can be confident that there will be minimal material waste.

Tolerances – Tolerance refers to the level of dimensional accuracy required for a machined feature. A significant contributing factor to the cost of a machined component is the tolerance required during manufacturing. Generally, the more accurate or tight a tolerance must be, the more the part will cost. We employ creative solutions while designing toolpaths to ensure parts will perform to their specifications at any level of tolerance.

Assembly Process Design – Some parts that will be cut will stand alone but many are designed to assemble with others. In these cases, we offer consulting and design services for assemblies. Important assembly process design factors we address include:

  • Hardware Selection – There is an enormous selection of hardware available. We utilize our vast practical design and fabrication experience to select appropriate hardware for your project needs.
  • Joinery Design – In many cases hardware is not desirable. We can help choose machined joints that will accommodate your strength and function needs as well as appeal to your aesthetic preferences.
  • Prototyping – We will prototype your products for approval. You will be able to test fit and function of your project and address desired adjustments which will be applied to future prototype iterations. This process ensures that you are only signing off on what you have seen directly before moving into production.
  • Embedded hardware design – In some cases hardware will be embedded in machined pockets. This is especially desirable for flat pack applications where parts should be easily assembled and disassembled with ease. We will test and prototype until optimum fit is achieved. These optimized features are easily applied to production files to guarantee ideal results across the entire production run.

Design and Shape – We work with you to utilize the most efficient and cost effective processes to accomplish your design goals. In many cases, some features require a substantial amount of tool movement. Machine time can be reduced by utilizing available tool geometries. Some features that would ordinarily require multiple carving passes can be created with single profile passes. Some shapes and features can be accomplished through a variety of approaches. We help determine which approaches will accomplish your goals most efficiently. We also optimize tool type, length, and diameter so that the tool may be fed through the material as quickly as possible while maintaining optimum finish. This results in substantial savings for you.

BOM (Bill of Materials) – A bill of materials is a list of the raw materials, hardware, assemblies, and other items needed to produce a final product. If you chose to go to this level of detail, while we are working with your product, we will be preparing a running list of all items needed to produce your product. We can prepare this list for your usage with quantities and cost at varying scales of production to help you understand the advantages and disadvantages to producing at varying levels of scale. When you are ready to produce at any scale you will have a very clear understanding of all the items, quantities, and costs required to produce your product when you have us prepare your BOM for you.

Pricing Structure