Manufacturing Processes

3D Printing

Choose from PC-ISO or ABS when printing to our 16”x14”x16” Build Envelope.

Urethane Molding

Create parts with complex geometry, while achieving maximum comfort and durability with this integral skin technology.

Fusion Molding

Fuse fasteners and other hardware directly into our Precision Cell Foam.

Thermo-Pressure Welding

Encapsulate electronics and other core materials with our PolyDry Healthcare Fabric, while achieving a soft, uniform seam.

Vacuum Forming

Foams, Films and thin gauge plastics can all be formed for your next packaging application.

Compression Molding

High level details and textures are created through heat and pressure.

CNC Contour Cutting

Precise angles and contours are achieved with this finite cutting process.

3 & 5-Axis Machining

With high spindle speeds and custom fixtures, machining complex foam parts is a breeze.

Additional Capabilities

Electronics Assembly

Certified technicians with cutting edge equipment allow us to manufacture to the highest standards.

Medical Device Testing & Repair

Our state of the art repair and testing facility makes us the best in the business.

Laminating Materials and Adhesives

Combining  materials can help elevate the functionality and effectiveness of many products.

Precision Die-Cutting

High speed die-cutting equipment is used for small parts that require accuracy and consistency.

Kitting

Let us manufacture or procure your desired parts and supply them to you together in a sterile or non-sterile kit.

Product Assembly

Complex parts can be achieved by combining multiple materials and technologies.

Private Labeling / Screen Printing

Add your company logo or identification markings on all your parts at no additional charge.

Product Design Assistance

Using the latest 3D CAD Software and other rapid prototyping tools, we can take your idea from conception to production.

Manufacturing Process

3D Printing

Choose from PC-ISO or ABS when printing to our 16”x14”x16” Build Envelope.

Urethane Molding

Create parts with complex geometry, while achieving maximum comfort and durability with this integral skin technology.

Fusion Molding

Fuse fasteners and other hardware directly into our Precision Cell Foam.

Thermo-Pressure Welding

Encapsulate electronics and other core materials with our PolyDry Healthcare Fabric, while achieving a soft, uniform seam.

Vacuum Forming

Foams, Films and thin gauge plastics can all be formed for your next packaging application.

Compression Molding

High level details and textures are created through heat and pressure.

CNC Contour Cutting

Precise angles and contours are achieved with this finite cutting process.

3 & 5-Axis Machining

With high spindle speeds and custom fixtures, machining complex foam parts is a breeze.

Additional Capabilities

Electronics Assembly

Certified technicians with cutting edge equipment allow us to manufacture to the highest standards.

Medical Device Testing & Repair

Our state of the art repair and testing facility makes us the best in the business.

Laminating Materials and Adhesives

Combining  materials can help elevate the functionality and effectiveness of many products.

Precision Die-Cutting

High speed die-cutting equipment is used for small parts that require accuracy and consistency.

Kitting

Let us manufacture or procure your desired parts and supply them to you together in a sterile or non-sterile kit.

Product Assembly

Complex parts can be achieved by combining multiple materials and technologies.

Private Labeling / Screen Printing

Add your company logo or identification markings on all your parts at no additional charge.

Product Design Assistance

Using the latest 3D CAD Software and other rapid prototyping tools, we can take your idea from conception to production.

Our Process

PROJECT QUALIFICATIONPROJECT QUALIFICATION

The first stage of our process involves qualifying project feasibility. We'll collaborate with you in reviewing your drawings, and ask questions pertaining to the geometry and intent of your part.

FOAM MATERIAL SELECTIONFOAM MATERIAL SELECTION

Stage two involves material review and selection. At this time we'll assess placement and indentation load deflection in identifying the right foam for your part.

FINISHING SELECTIONFINISHING SELECTION

After the right foam is identified, we'll determine any coating or fabric necessary for your part's specialized application.

PROTOTYPINGPROTOTYPING

In creating your perfect part, we make sure to deliver the right prototype. We have multiple prototyping capabilities including 3D printing. This often times allows us to produce, coat or cover, and ship a prototype to you within 24 hours.

TOOL, DIE, MOLD CREATIONTOOL, DIE, MOLD CREATION

After the prototype is approved, we determine the manufacturing process necessary to deliver your part in the most efficient manner. Tools and dies are made at this stage.

PRODUCTIONPRODUCTION

During production your part is manufactured to meet supply needs. This involves cutting, sawing, milling or molding the selected foam, and coating or encapsulating it in fabric per specifications.

ASSEMBLYASSEMBLY

We take great care in providing additional services in the assembly of your product. This can even include component sourcing and the encapsulation of electronics.

SPECIALTY PACKAGINGSPECIALTY PACKAGING

We are happy to complete the processing of your order by providing any necessary specialty packaging.