Custom Mechanical Manufacturing Solutions
Project Delivery Case Examples
Real program stories showing how we take complex mechanical designs from concept to validated production — covering engineering, DFM/DFMA, prototyping, process selection, tooling, test & qualification, supply chain and fulfillment.
20k/yr typical ramp for EV systems | 98.5% cosmetic yield on molded housings |
EV Inverter Cold Plate — High‑Power Thermal Module
Consumer Electronics Housing — Cosmetic & Cost Target
LSR Medical Valve Seal Cleanroom Production
Why Leading Innovators Choose Us
Thermal Engineering Expertise That Sets Us Apart
Proven modeling, CFD and test correlation for high‑power systems — from cold plates to integrated heat sinks. We validate with thermal mapping and production-level test methods.
Multi‑Process Integration Under One Roof
Injection molding, die casting, extrusion, CNC, sheet metal and assembly — coordinated for DFM and efficient NPI. We optimize sequence and tooling to reduce cost and schedule risk.
Engineering‑Driven Cost Optimization
Design for manufacture, tool strategy and sourcing reduce piece cost while preserving performance and cosmetic requirements. We gate NPI against measurable metrics.
Our Manufacturing Capabilities
From prototype to production — process engineering, tooling, validation and serialized assembly delivered with quality systems and supply chain alignment.
1
Manufacturing Processes
CNC, FSW, die casting, extrusion, injection molding, LSR, progressive stamping and turnkey box‑build.
2
Testing & Validation
Thermal cycling, vibration, CT/X‑ray, extractables, PPAP/FAI and Cpk analysis to validate processes and parts.
3
Quality & Traceability
MES lot traceability, serialized box‑build, SPC and documented NPI gates for regulated and critical applications.
Selected Case Studies
EV Inverter Cold Plate High‑Power Thermal Module
Challenge: a liquid cold plate to handle 30 kW continuous dissipation with tight sealing faces, low pressure drop and manufacturability for automotive volumes.
Approach
- Material: machined aluminum A356 cold plate with CNC‑milled sealing datums and FSW/laser weld sealing.
- Thermal & CFD simulations to size channels and predict pressure drop; design for FSW seam to ensure leak tightness.
- Prototype: 5x machined validation units (CNC + pressure test + thermal mapping).
- Validation: thermal cycling, leak and vibration testing to automotive requirements. FAI package and Cpk studies performed during pilot runs.
Outcomes
- Result: reduced junction temperature by ~10% vs initial concept; achieved leak‑tight seams with FSW and passed 1000‑cycle thermal shock.
- Volume ramp: 20k units/year using robotic FSW and automated CNC finishing for datums.
- Key metrics: seal leak rate <1e‑3 mbar·L/s; process Cpk >1.67 on critical datums.
Services used
- CNC machining, FSW, thermal simulation, pressure testing, CMM, NPI & supply chain.
Timeline: 14 weeks (concept → pilot). Volume: 20k/yr.
Consumer Electronics Housing — Cosmetic & Cost Target
Challenge: move from machined prototypes to low‑cost multi‑cavity injection molded housings with consistent texture and tight assembly tolerances.
Approach
- Material: machined aluminum A356 cold plate with CNC‑milled sealing datums and FSW/laser weld sealing.
- Thermal & CFD simulations to size channels and predict pressure drop; design for FSW seam to ensure leak tightness.
- Prototype: 5x machined validation units (CNC + pressure test + thermal mapping).
- Validation: thermal cycling, leak and vibration testing to automotive requirements. FAI package and Cpk studies performed during pilot runs.
Outcomes
- Result: reduced junction temperature by ~10% vs initial concept; achieved leak‑tight seams with FSW and passed 1000‑cycle thermal shock.
- Volume ramp: 20k units/year using robotic FSW and automated CNC finishing for datums.
- Key metrics: seal leak rate <1e‑3 mbar·L/s; process Cpk >1.67 on critical datums.
Services used
- DFM, prototype tooling, production tooling, painting & final assembly.
Timeline: 20 weeks to hardened tool. Volume: 500k+ units/yr.
LSR Medical Valve Seal — Cleanroom Production & Low Extractables
Challenge: develop an LSR valve seal meeting ISO 10993 extractables limits, automated trimming, and full lot traceability in ISO 7 production.
Approach
- Compound selection with low extractables, validated via extractables testing and material certificates.
- Stainless steel LSR tooling with mirror polish for cosmetic/functional zones; automated metered LSR cells and inline post‑cure ovens.
- Cleanroom flow: ISO 7 molding cells, automated trimming and lot tracking (MES integration).
Outcomes
- Passed extractables targets and ISO 10993 screening; achieved automated throughput to meet 100k parts/yr with per‑lot traceability.
- Reduced scrap from manual trim >70% by automating degating and vision inspection.
Services used
- LSR tooling, cleanroom molding, post‑cure, extractables testing, MES lot traceability.
Timeline: 10 weeks (tooling & validation). Volume: 100k/yr.
Die‑Cast Aluminum Housing Porosity Mitigation for Structural Use
Challenge: produce a die‑cast housing with minimal porosity for a structural mount while maintaining cosmetic finish for visible surfaces.
Approach
- Selected A356 with vacuum die casting and optimized gating to minimize turbulence and shrink porosity.
- CT/X‑ray qualification on pilot castings and iterative gating/riser tuning.
- CNC finish on sealing faces and anodize on visible surfaces with DFF allowances.
Outcomes
- CT porosity reduced to acceptable levels for fatigue requirements; housing passed structural load tests.
- Production: hardened dies with replaceable inserts, scheduled die maintenance and FAI/PPAP deliverables.
Services used
- Die casting (vacuum), CT inspection, CNC finishing, anodize & NPI.
Timeline: 16 weeks to production tool. Volume: 50k/yr.
Extruded Thermal Rail with Integrated Channels
Challenge: extrude an aluminum thermal rail with internal coolant channel and tight end‑face tolerances for assembly into a modular system.
Approach
- Die design with internal mandrel for coolant passage, vacuum sizing for dimensional control, and downstream CNC end‑machining for sealing faces.
- Prototype soft die validation followed by hardened die production; anodize and coiling for transport.
Outcomes
- Delivered kitted rails with machined sealing faces and anodize finish; reduced assembly time by integrating O‑ring grooves and indexing features in the extrusion.
- Accepted into OEM production with VMI and Dallas warehousing support.
Services used
- Extrusion die design, vacuum sizing, CNC machining, anodize, kitting & fulfillment.
Timeline: 12 weeks. Volume: 30k linear meters/yr.
Progressive Stamped Bracket with In‑Die Clinch
Challenge: produce a high‑volume multi‑feature bracket replacing an assembly of stamped parts and fasteners.
Approach
- Engineered a progressive die with in‑die clinch and thread forming to eliminate secondary assembly steps.
- Strip layout optimized to reduce blank size and scrap.
Outcomes
- Eliminated 6 assembly steps, reduced piece cost by 40% and improved throughput to support 200k/yr.
- Implemented die life program with spare inserts and scheduled PM.
Services used
- Progressive tooling, die tryout, SPC, in‑die tapping & final assembly integration.
Timeline: 14 weeks. Volume: 200k/yr.
Turnkey Box‑Build for Power Electronics — Box, Harness & Test
Challenge: integrate PCBAs, cold plate, harness and final test into a serialized box‑build with OEM test scripts and burn‑in.
Approach
- Developed ICT+FCT fixtures, burn‑in racks and firmware provisioning flows; designed harness routing and custom torque & leak test procedures.
- Implemented MES traceability with per‑unit logs and failure capture.
Outcomes
- Delivered 5k units/year with per‑unit traceability, 48‑hour burn‑in and automated pass/fail logging to MES; streamlined RMA workflows via serial history.
- Improved first‑pass yield from 86% to 96% via test fixture and DFT improvements.
Services used
- Box‑build, harness assembly, ICT/FCT/ATE development, burn‑in, serialization & fulfillment.
Timeline: 10–12 weeks for fixturing & pilot. Volume: 5k/yr.
When to Apply Cost Optimization in Your Program
Cost optimization is most powerful when it’s threaded throughout the development process—not saved for the final RFQ.
Concept & Architecture
- Align on major process choices and part count
- Avoid locking in overly complex concepts
- Set realistic cost and performance targets
Design & EVT
- Apply DFM / DFMA to initial drawings and models
- Prototype with cost in mind, not just speed
- Start building your cost database early
DVT / PVT
- Validate actual process capability and yield
- Refine tolerances, finishes, and inspection plans
- Lock tooling strategies and capacity plans
Mass Production & Sustaining
- Monitor scrap, rework, and field issues
- Execute continuous improvement & cost‑down projects
- Adjust volumes, tooling, and logistics as demand shifts
Repeatable Delivery Playbook Key Lessons
- Early cross‑functional DFM: involving manufacturing, test, sourcing and quality at concept reduces redesign and shortens NPI.
- Prototype-to-tooling cadence: use soft tooling for fit/function, then hardened tooling once process windows are proven.
- Design for testability (DFT): ensure PCBA & assembly accommodate ICT/FCT and root‑cause data capture.
- Supply chain qualification: dual sourcing for long‑lead items, sample panels for finishes and pre‑approved spare inserts for dies.
- Metrics & gating: define acceptance criteria (Cpk, yield, performance) and gate NPI passes against them.
How to Start
To evaluate your project, please upload: CAD assemblies (STEP/IGES), BOM, target volumes, performance requirements and any regulatory constraints. We return a recommended manufacturing route, high‑level cost estimate and NPI timeline — typically within 24 business hours.
