We offer several added services to supplement our primary prototype offerings. These include:

Metrology has always been a time-consuming process. While automated measurement has come a long way since the first programmable CMMs and comparators of the early '80s, most systems have lacked the level of detail and the level of accuracy needed to truly replace a human metrologist. They have also tended to be complex to use from a procedural standpoint, with often tedious calibration, alignment, and programming requirements.

After extensive research, we found an exception to the rule, and invested in a GOM (Gesellschaft für Optische Messtechnik) ATOS II s.o. 3-D optical scanner for non-contact metrology. The system shines patterns of 'structured' light onto an object, then uses the resulting lines of contrast with high precision binocular cameras to accurately triangulate surface and feature positions. Our custom part fixtures can often enable the scanning of all important part surfaces in a single fixturing setup.

Our GOM camera system, and two axes of our 6-axis automation system

Our system is equipped with an efficient software interface for planning and capturing scan data, and includes a six-axis automation enclosure to capture data from many angles. For scanning a typical part, we perform anywhere from 15 to 45 scans. Our software tools automatically align and merge the scan data, and perform a best-fit alignment to an imported CAD database. This eliminates a significant amount of time and labor in performing a scan, and also avoids many opportunities for error.

Additional software tools enable us to perform detailed comparisons between scanned part and data base, or among several scanned parts. In addition to a compiled report in .PDF format, we can also provide an .STL file of the scan data, or an interactive .SESSION file that can be interrogated in depth by the requesting engineer using a free downloadable program.

We have also added some powerful data post-processing services. These include reverse engineering of the scan data to create an fully editable parametric CAD file in either a generic format or a program specific version such as Pro/ENGINEER, and the ability to perform a Rapid FAIR analysis, automatically generating a First Article Inspection Report across multiple parts based on the customer's supplied 3-D design file and 3-D GD&T tolerances.

Moldflow simulation of a connector

We can provide Moldflow simulation to help evaluate new parts prior to tooling investment, and can also provide simulation support in cases where existing parts are not behaving as desired. Customers can use this information to determine whether the most likely causes are tooling, material, process, supplier, or design issues, and evaluate the effect of a proposed correction.

Moldflow can be used to determine confidence of fill for a part design, quantify and display shrinkage behavior, determine which of several materials will provide the lowest warpage, highlight weld lines and other stress areas with reduced part strength, and estimate the cycle time required for molding parts.

If valid design data is available, a basic series of simulation runs can be completed in a few hours to a few days. Issues with the quality of the CAD database (will not regenerate, submerged or orphaned elements, slivers) can prevent automatic mesh generation and increase the time required for a simulation. We can work with designers to help validate data, and create efficient models for analysis.

Tracker assembly exploded views - Mechanicals PCBs and a few Sourced Parts

Occasionally our customers have projects which involve multiple suppliers, or evolve over multiple stages. In these situations we often provide project management services, coordinating a series of activities to ensure our customers' needs are met. This makes use of our project management, purchasing, and technical skills, and gives our customers a single point of control.

Typical examples are where a business wants to produce a limited batch (i.e. 10-100 units) of a conceptual product for technology demonstration or marketing purposes. These projects can start from 'scratch', or may involve re-purposing elements from an existing product, combined with new off-the-shelf and custom fabricated prototype components.