Manufacturing Process
PHASE 01
Engineering & Design
The process begins with high-fidelity 3D modeling of parts derived from customer-supplied components or precision scans. Designs undergo rigorous customer review and approval before proceeding to tool design and validation through advanced forming simulation.
PHASE 02
Pattern, Cast Development & Machining
Validated designs are translated into precise Thermocol patterns. These patterns serve as the blueprint for CI casting the tools, which are then machined to exact specifications to match the final tool design requirements.
PHASE 03
Polishing & Sample Production
Machined tools undergo meticulous hand polishing and press setup to ensure flawless operation. A first sample piece is produced and submitted to the customer for final verification and approval of fit and finish.
PHASE 04
Low-Volume Production
Upon receiving explicit customer approval of the first sample, the tools are authorized for the low-volume production run, ensuring consistent quality and precision across the entire batch of panels.
Engineered Case Studies
A technical overview of precision manufacturing and low-volume production workflows.
VW Split-Screen Bus Panels
Customer-supplied reference parts were 3D scanned, modelled, and tooled via forming simulation. The resulting CI cast tooling was machined, hand-polished, and then stamped in low volumes for global restorers.
Fender Flare Development
We developed custom flare geometry from scan data, validating tooling through intensive forming simulation. This ensured repeatable, high-precision low-volume flares for premium restomod builds.
Classic Panels
Highlighting the recreation of complex geometry using 3D design, CI cast tooling, and precise hydraulic press stamping for long-term serviceability and structural integrity.