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Explore our comprehensive portfolio of engineering solutions across three key areas: Design for Manufacturing, Quality Control Systems, and Design & Packaging Solutions.
Design for Manufacturing optimization case studies
DFM Solutions
The client required a highly accurate and efficient propeller for a new class of performance yacht. The complex blade geometry could not be achieved with traditional casting and grinding methods. We used simultaneous 5-axis CNC milling to machine the entire propeller from a single Nibral (Nickel Bronze Aluminum) casting, resulting in a perfectly balanced and hydrodynamically optimized propeller.
DFM Solutions
Ford Motor Company's Dearborn Engine Plant reduced manufacturing costs by 32% and improved production efficiency by 28% through comprehensive DFM optimization of their V8 engine mount bracket assembly. The project eliminated secondary operations and standardized fastening methods across three vehicle platforms.
DFM Solutions
MedDevice Corp needed to reduce manufacturing costs for their diagnostic equipment housing while maintaining strict medical device quality standards. Initial design had 45% rejection rates due to warping and dimensional issues.
DFM Solutions
Samsung Electronics reduced injection molding cycle times by 41% and achieved 95% first-pass quality rates through comprehensive DFM redesign of their Galaxy tablet housing components. The optimization eliminated post-molding operations and integrated advanced cooling channel design for high-volume production.
DFM Solutions
AeroTech Industries faced excessive machining costs and long lead times for critical flight control components. Complex geometries required specialized tooling and multiple setups, driving costs 340% above target.
DFM Solutions
Medtronic's Memphis facility achieved 43% reduction in machining time and 99.97% quality compliance for titanium hip implant stems through advanced DFM optimization. The project eliminated 12 secondary operations while maintaining FDA Class III medical device requirements and ISO 13485 quality standards.
DFM Solutions
ElectroCase Manufacturing struggled with complex sheet metal designs requiring extensive secondary operations. Their telecommunications equipment enclosures had 23 separate forming operations and costly welding requirements.
DFM Solutions
Boeing's Renton facility reduced assembly time by 52% and achieved 99.8% dimensional accuracy for 737 MAX engine nacelle components through innovative DFM strategies. The optimization eliminated 28 fasteners and consolidated 15 sheet metal parts into 7 integrated components while maintaining FAA certification requirements.
DFM Solutions
AutoCast Solutions needed to optimize their transmission housing design for high-pressure die casting. Original design had 28% scrap rate due to porosity and dimensional issues affecting critical sealing surfaces.
DFM Solutions
Whirlpool Corporation achieved 37% cycle time reduction and 94% first-pass quality rates for dishwasher pump housing components through advanced die casting DFM optimization. The project eliminated secondary machining operations and integrated advanced cooling systems for high-volume production exceeding 280,000 units annually.
DFM Solutions
PlasticTech Innovations faced assembly challenges with their consumer electronics housing requiring 12 separate components and extensive ultrasonic welding. Assembly time exceeded 8 minutes per unit with 15% failure rate.
DFM Solutions
Emerson Process Management reduced machining time by 48% and achieved 99.7% dimensional compliance for critical flow control valve bodies through innovative DFM strategies. The optimization consolidated 22 machining operations and eliminated custom fixturing requirements while maintaining ASME B16.34 pressure vessel standards.
DFM Solutions
Cisco Systems achieved 44% reduction in stamping operations and 96% first-pass quality rates for 5G network equipment enclosures through progressive die optimization. The project eliminated secondary operations and integrated EMI shielding features while meeting FCC electromagnetic compatibility standards.
DFM Solutions
Blum Inc. reduced forging operations by 55% and achieved 98.4% dimensional accuracy for concealed hinge components through innovative hot forging DFM strategies. The project eliminated machining operations and integrated precision forming capabilities while maintaining 200,000-cycle durability requirements.
DFM Solutions
Tetra Pak reduced welding operations by 61% and achieved 99.2% weld quality compliance for packaging machine structural frames through integrated weldment design optimization. The project eliminated post-weld machining and integrated sanitary design features meeting FDA food contact requirements.
DFM Solutions
General Dynamics Mission Systems achieved 49% reduction in manufacturing time and 97.8% structural integrity compliance for composite UAV wing assemblies through advanced resin transfer molding DFM optimization. The project eliminated secondary bonding operations while meeting MIL-STD-810 environmental requirements.
DFM Solutions
The client required a lighter, more efficient gripper arm for their new line of assembly robots without compromising strength. Through strategic DFM analysis, we optimized the design for CNC milling, reducing part weight by 18% and decreasing cycle time, which directly improved the robot's operational speed and energy consumption.
DFM Solutions
The client required a mounting component for a new laser spectrometry device with extreme dimensional stability and tight tolerances to ensure precise optical alignment. We CNC machined the component from 316L stainless steel, holding a flatness tolerance of 0.005mm and positional tolerances of ±0.01mm, ensuring perfect, repeatable alignment of the sensitive optics.
DFM Solutions
The client required a complete kit of custom-machined components for a new robotic sorting machine prototype. By providing an integrated manufacturing solution for four unique parts and offering key DFM feedback, we delivered a full set of components with guaranteed fitment, consistent finishes, and a 25% reduction in their final assembly time.
Advanced quality assurance and control implementations
Quality Control Systems
A leading aerospace components manufacturer transformed their quality control operations by implementing a comprehensive coordinate measuring machine (CMM) system, reducing dimensional inspection time by 75% while achieving 99.97% measurement accuracy. The integration of automated CMM systems with statistical process control eliminated critical dimensional defects and established real-time quality monitoring across production lines.
Quality Control Systems
Ford Motor Company's Dearborn stamping plant revolutionized surface quality control by implementing advanced optical inspection systems, reducing surface defect escapes by 94% while increasing inspection speed by 300%. The integration of machine learning algorithms with high-resolution imaging technology established automated defect classification and real-time quality monitoring for critical body panel components.
Quality Control Systems
Pfizer's Dublin facility implemented comprehensive statistical process control (SPC) systems across critical drug manufacturing processes, achieving 99.8% process capability while reducing out-of-specification events by 87%. The real-time monitoring system integrated with automated sampling and testing equipment established continuous process verification and proactive quality control for high-volume pharmaceutical production.
Quality Control Systems
Apple's contract manufacturer Foxconn implemented advanced X-ray inspection systems for printed circuit board assembly, achieving 99.5% defect detection accuracy while reducing inspection time by 60%. The automated inspection system integrated machine learning algorithms with high-resolution X-ray imaging to identify hidden solder joint defects, component placement errors, and internal assembly issues in high-density electronic assemblies.
Quality Control Systems
ASML's Veldhoven facility implemented advanced laser interferometry measurement systems for semiconductor lithography equipment manufacturing, achieving nanometer-level measurement accuracy while reducing calibration time by 80%. The implementation of real-time position feedback and environmental compensation established unprecedented precision control for critical optical components and stage positioning systems.
Quality Control Systems
Medtronic's Minneapolis facility transformed quality control for cardiac catheter manufacturing by implementing automated dimensional inspection systems, achieving 99.99% measurement accuracy while reducing inspection time by 85%. The integration of high-resolution optical measurement with statistical process control established real-time quality monitoring for critical medical device dimensions and eliminated dimensional defects that could compromise patient safety.
Quality Control Systems
Boeing's Everett facility implemented advanced ultrasonic testing systems for composite aircraft structures, achieving 99.8% defect detection reliability while reducing inspection time by 70%. The automated phased array ultrasonic testing system integrated with digital imaging and artificial intelligence established comprehensive non-destructive evaluation for critical carbon fiber reinforced polymer (CFRP) components in commercial aircraft manufacturing.
Quality Control Systems
ArcelorMittal's Indiana Harbor facility implemented comprehensive real-time process monitoring systems for steel production, achieving 98.5% yield improvement while reducing quality defects by 76%. The integration of advanced sensors, predictive analytics, and automated process control established continuous quality optimization across blast furnace, basic oxygen furnace, and continuous casting operations.
Quality Control Systems
PepsiCo's Frito-Lay facility implemented advanced machine vision systems for snack food quality inspection, achieving 99.7% defect detection accuracy while processing 2,500 units per minute. The integration of hyperspectral imaging, artificial intelligence, and automated sorting systems established comprehensive quality control for color, shape, size, and foreign object detection in high-speed food manufacturing operations.
Quality Control Systems
General Electric's Lynn facility revolutionized turbine blade inspection by implementing advanced eddy current testing systems, achieving 99.9% crack detection reliability while reducing inspection time by 65%. The integration of multi-frequency eddy current arrays with automated handling systems and AI-powered analysis established comprehensive non-destructive evaluation for critical engine components, ensuring flight safety and operational reliability.
Innovative design and packaging engineering solutions
Design & Packaging Solutions
TechWave Electronics faced critical packaging challenges with 12% failure rates due to electrostatic discharge damage in high-frequency RF components. This case study details the development of a multi-layer anti-static packaging solution that reduced failure rates to 0.3%.
Design & Packaging Solutions
Quantum Precision Instruments required advanced packaging for ultra-sensitive laser interferometers capable of detecting displacements as small as 10^-18 meters. Thermal-induced calibration drift during shipping resulted in costly recalibration procedures at customer sites.
Design & Packaging Solutions
OpticalVision Systems faced significant challenges protecting delicate optical components during global shipping, with their flagship Model OV-5000 systems experiencing 15% damage rates during transportation, primarily affecting critical optical elements.
Design & Packaging Solutions
MicroTech Manufacturing faced significant packaging inefficiencies due to their diverse product portfolio with over 2,400 unique part numbers, requiring 180 different package configurations and resulting in substantial inventory costs and storage complexity.
Design & Packaging Solutions
SteelCraft Industries faced increasing pressure to reduce their environmental footprint while maintaining superior protection for high-value precision components. Their traditional packaging generated 240 tons of waste annually and failed to meet corporate sustainability commitments.
Design & Packaging Solutions
Development of multi-layered shock-absorption packaging system for Medtronic's precision surgical instruments, reducing transport damage by 89% and ensuring sterility compliance across global distribution networks.
Design & Packaging Solutions
Implementation of advanced phase-change material packaging and real-time temperature monitoring for Pfizer's biologics distribution, maintaining 2-8°C cold chain integrity for 120+ hours while reducing temperature excursions by 94%.
Design & Packaging Solutions
Development of conductive foam cushioning system for Intel's 5G chipset modules, providing ESD protection while maintaining signal integrity through frequency-selective shielding and precision shock absorption during global distribution.
Design & Packaging Solutions
Engineering of advanced honeycomb composite cushioning for Boeing's satellite components, achieving 78% weight reduction while providing superior protection against launch vibrations and reducing shipping costs by $2.4M annually.
Design & Packaging Solutions
Development of micro-climate packaging system for Sotheby's high-value art shipments, providing precise humidity and temperature control with integrated shock protection, reducing damage claims by 96% for $50M+ artwork transactions.
Design & Packaging Solutions
Implementation of innovative mycelium-based packaging for Caterpillar's hydraulic systems, replacing traditional wood crating with biodegradable alternatives while maintaining 15-ton load capacity and reducing environmental impact by 87%.
Design & Packaging Solutions
Development of ultra-clean vacuum packaging system for Thermo Fisher's analytical instruments, providing complete atmospheric isolation with integrated desiccant systems, eliminating contamination damage and reducing calibration drift by 94%.
Design & Packaging Solutions
Creation of intelligent modular packaging system for Ford's electric vehicle battery modules, featuring automated configuration adjustment and reusable components, reducing packaging costs by 67% while improving protection efficiency for $45,000+ battery systems.
Design & Packaging Solutions
Engineering of next-generation ESD protection system for NVIDIA's AI accelerator chips, utilizing triboelectric charge dissipation and electromagnetic shielding, reducing static damage by 99.2% while enabling automated handling of $25,000+ processors.
Design & Packaging Solutions
Development of precision climate-control packaging system for Moët Hennessy's rare vintage collections, maintaining optimal temperature and humidity while preventing vibration damage, reducing product loss by 91% for $5,000+ bottles during global distribution.