Case Study

Challenge: Develop a complex, miniature component for a new minimally invasive surgical tool. Solution: Utilized advanced 5-axis CNC milling to create high-precision parts from medical-grade titanium.

Process:

• Collaborated with the client to optimize the design for manufacturability
• Developed a custom fixturing solution for the intricate part
• Implemented rigorous quality control measures to meet FDA standards Results:
• Achieved tolerances of ±0.005mm, exceeding client expectations
• Reduced production time by 30% compared to traditional methods
• Enabled the client to secure a patent and fast-track FDA approval

Challenge: Rapidly iterate on a smart sports watch design before finalizing for mass production. Solution: Employed a combination of SLA 3D printing and vacuum casting for prototyping.

Process:

• Used SLA for initial concept models and fit tests
• Created silicone molds for vacuum casting functional prototypes
• Provided surface finishing to achieve production-quality aesthetics Results:
• Produced 20 iterations in just 6 weeks
• Saved the client an estimated $100,000 in tooling costs for design changes
• Helped the client launch 3 months ahead of schedule

Challenge: Transition from low-volume production to meeting growing market demand for a smart thermostat. Solution: Implemented a hybrid approach using CNC machining and injection molding.

Process:

• CNC machined critical components requiring high precision
• Developed rapid tooling for injection molding of housing parts
• Established an assembly line for final product integration Results:
• Scaled production from 500 to 10,000 units per month
• Reduced per-unit cost by 40% through optimized manufacturing
• Maintained consistent quality across increased production volume

Challenge: Create lightweight yet durable control panel housings for a new aircraft model. Solution: Utilized advanced sheet metal fabrication techniques with aerospace-grade aluminum.

Process:

• Collaborated on design to optimize for weight reduction
• Implemented precision laser cutting and CNC bending
• Developed a custom anodizing process for corrosion resistance Results:
• Achieved a 25% weight reduction compared to previous models
• Met stringent aerospace quality standards with zero defects
• Helped the client secure a major contract with a leading airline

Challenge: Produce a market-test run of 5,000 units for a new educational toy before committing to full production tooling. Solution: Developed rapid tooling for injection molding, combined with 3D printed inserts for changeable features.

Process:

• Created aluminum tooling for the main body parts
• 3D printed interchangeable inserts for different product variations
• Established a flexible assembly process for various product configurations Results:
• Delivered 5,000 units in 4 weeks, meeting the client’s launch deadline
• Allowed for mid-run design tweaks based on initial market feedback
• Provided a smooth transition to full production, saving 6 weeks in time-to-market