It all starts with an idea. Say,
for instance, that we need to create a flashlight mount that pivots at nearly
any angle. We will make a preliminary sketch and then carefully determine
actual dimensions. This initial concept is programmed into a CNC milling
machine, and the prototype phase begins. We do everything in house which lets
us flow from idea to working prototypes in as little as a few days. After we
have a few of these working models, we then test some for function and
durability, and a handful are sent out to a select few trusted individuals to
provide real world feedback and stress testing. It depends on the complexity of
the product, but this process typically takes a few months.
Based on user feedback and the results from
our own testing, the original design is modified into a finished product and a
small run of the mount is made. We prefer to do it this way because having a
physical prototype to inspect lets us refine the product in ways that computer
modeling simply can’t match. Once the product is as close to perfect as we can
get it, our marketing team photographs it and builds a product page on our
website. Months of effort are now reflected in a new product offering.
Now comes the production phase
which requires special tooling and extrapolating the original machining setups
to a larger machine for increased volume. Sourcing the hardware from
manufacturers domiciled in the USA comes next. We prefer to use existing
hardware whenever possible, so some elements are initially designed to
accommodate a commonly available fastener. This makes designing simpler for us
and works in favor of the end user as getting replacement screws is easy should
the need arise. We try to keep in the mind the things that we would want from a
product and design team if the roles were reversed.
We get billets of aluminum or steel
delivered depending on the part, and they are then cut to size to fit into the
CNC machines. There is an initial setup that involves determining the specific
tooling required and gathering it all to be loaded into the machine. Once setup
is complete, the CNC operator has their work double checked and signed off.
Every product undergoes a rigorous checklist during machining, and each operation
must be accompanied by an authorized signature. This is critical, as the product
is a mechanical device, and one out of spec part can deadline the entire
assembly. In fact, the inspection area is in the assembly room. This ensures
that the inspector can test fit each first run component in its proper
application. The CNC machines don’t make mistakes, and any issue can be traced
to human error - that is how accurate they are. Once the operation is finished,
the parts are tumbled in a vibratory box filled with mildly abrasive media.
This process is done between every operation to erase light machining marks and
remove burrs.
After tumbling, each part is bead
blasted to a specific surface finish and then hard anodized (if aluminum). Hard
anodization is an ultra-durable, corrosion resistant “skin” of hard oxide. This
not only mitigates wear, it also provides a tangible strength benefit to the
part. We are very particular about the cosmetic appearance of our products and
routinely reject any parts that have discoloration after the anodization
process. All steel fasteners are manganese phosphate coated in house to
mil-spec standards. Each individual component is then organized in the assembly
room in a series of labeled bins. When we get an order, all the parts necessary
to assemble the mount are pulled from their bins and re-checked for cosmetic
appearance. It is then assembled using specialized tools and torque wrenches.
Each mount is tested three separate times for fit and function on a series of
test rails before it’s cleared to leave our facility. It is then boxed up and
shipped off for a lifetime of reliable service to you – our valued customer.
