Unlike most design firms which simply provide a drawing package to their clients and ignore the eventual production startup challenges, we provide continued support as long our clients request assistance. Many of our projects require additional technical support during vendor selection, tooling, molding and assembly. Production liaison involves a combination of skills including a thorough understanding of the design intent, manufacturing methods, material behavior, and a keen analytical methodology to solve complex problems frequently associated with tolerance stack-ups. Our extensive experience with production start-ups for a wide range of products benefits enables us to solve problems quickly and efficiently. Identification of subtle problems associated with warpage, tolerance stack-ups, improper assembly procedures or unexpected structural issues requires methodical analysis and astute observational skills. These photos depict moments during which we provided production startup support to our clients.

Pre-Production Tolerance Analysis

During the assembly of this silicon wafer inspection system, we assisted our client in identifying minor tolerance stackups between doors and panels.

Pre-Production Assembly Review and Analysis

Low production volume medical products are typically designed with a multitude of materials and processes to satisfy aesthetic, functional and investment requirements. These products require a comprehensive knowledge of multiple disciplines during the evaluation stages of production startup.

Ease of Assembly Analysis and Verification

These vacuum formed door panels were inspected shortly after installation to assure our client that the production parts and installation could easily be repeated on a production basis.

Comprehensive Design for Manufacturing Analysis

Our visits to contract manufacturing sites during production start ups have enabled us to assist our clients in virtually every step of the assembly process.

Extensive Experience in Diverse Manufacturing Processes

Our extensive experience with numerous manufacturing processes as well as a diverse range of products has provided us with the ability to quickly solve minor production startup difficulties during all stages of the manufacturing process.

Materials Expertise and Extended Technical Support

It doesn't matter whether the product is a room sized inspection system or a tiny hand held optical medical instrument. We support our clients with technical support based on design, processing and materials expertise.

Production Startup and First Article Inspection

We frequently assist our clients during molding trial runs. Molded parts are inspected for dimensional accuracy and assembled to other components to verify fit as well as function. These pictures show parts being molded and assembled to this medical device for Dupont´s medical division.

Assistance in Design and Introduction of Assembly Fixtures for Improved Quality

Our technical support is sometimes provided during molding or fabrication of individual parts as well as overall sub-assemblies. We have also assisted both vendors and clients in developing production fixtures as well as identifying critical dimensions to assure consistent quality from the first to last part.