The Cost Curve · Why Timing Matters
The same design change that costs hours in CAD costs weeks of tooling rework after T1, and a recall after launch. Catching issues early is the single highest-leverage decision in hardware.
Relative Cost of a Design Change
Service Scope
Every surface, wall, rib, boss, snap fit, and interface is reviewed against injection molding and assembly requirements. We identify risks before they become tooling changes.
We assess whether your design can be injection molded as-is, what modifications are required, and what the tooling implications are at your expected production volume.
Complete manufacturing documentation package ready to send to injection molding suppliers, CNC shops, and assembly vendors without back-and-forth.
We support tooling kick-off, FAI (First Article Inspection), tool trial reviews, and pilot production, guiding you through the critical transition from prototype to production parts.
Engagement Format
We review your existing CAD, prototype photos, and known issues to understand the current state.
Comprehensive review identifying all manufacturing risks, with prioritized recommendations.
We resolve identified issues in CAD, updating the design for production readiness.
Complete vendor package and support through tooling kick-off and first article.
This Engagement Is For You If
What You Walk Away With
Refined 3D models with manufacturing-aware geometry, tolerances, and assembly intent baked in.
Detailed 2D drawings with tolerances, finishes, datums, and critical-to-function callouts.
Itemized findings, severity, and recommended changes, written so suppliers and founders both understand it.
Materials, finishes, vendors, and a complete mechanical BOM ready for quoting.
We sit between you and the toolmaker: reviewing tool design, gates, ejection, and parting lines.
First article inspection support, tool trial reviews, and pilot build readiness.
Frequently Asked Questions
A prototype is ready for production when it has been reviewed for injection molding feasibility, all manufacturing risks are identified and resolved, tolerances and material selections are confirmed, and complete vendor documentation exists. Most prototypes need significant refinement before they can be injection molded. That is exactly what this service addresses.
A DFM (Design for Manufacturing) review includes analysis of wall thickness, draft angles, rib and boss design, snap fit geometry, gate location planning, undercut identification, tolerance stack analysis, material selection review, and surface finish specification. The goal is to identify every manufacturing risk before tooling begins.
Yes. This is the ideal time to engage. DFM review before tooling is the most cost-effective stage to resolve manufacturing issues. Changes at the design stage cost a fraction of changes after tooling has started. We recommend a comprehensive DFM review as early as possible in the production planning process.
Yes. We create complete vendor-ready documentation packages including detailed 2D drawings with GD&T, assembly drawings, test and inspection requirements, approved materials lists, and surface finish specifications. We also support tooling kick-off, first article inspection, and pilot production coordination.
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