Custom Machines, Tools & Fixtures

Machine Design For Working Faster and Better

Be Faster, Cheaper & More Consistent
with a Specialized Custom Machine

Machinery is all about making life simpler, easier and faster; and the right custom machine design makes all the difference. When it’s reliable and tuned to the demands of your business, it certainly helps in meeting business goals.

Saving time, money, and creating a safer environment are what machines do best. Whether it’s a fully automated Machine, a custom Tool, a simple Jig, a special process Fixture — Custom helps get things done.

Safer, Faster, More Efficient

If you’re combating production overloads, breaks, trying to improve precision, or looking to create a safer, faster process — consider custom machine design as an answer. Custom tools are similar, just on a smaller scale, and we design those too.

Make your processes Faster, Cheaper, Safer and Better with Custom Tools, Fixtures, Jigs and Machines.

Explore Possibilities

Think Synthesis . . .

For Custom Machines.

Building a custom machine is a big decision. Hiring Synthesis to assist is easy. Custom machine design in many unique flavors — From large automated manufacturing or testing machines on down to process expediting tools. Our job is to help find a path to higher efficiency, greater consistency — ultimately to make your business produce better.

For Specialized Tools.

Machines are a type of Specialized tool — as are dozens of other special fixtures and jigs and custom bits that help get the jobs done. Whatever you call them, whether big, or small — simple or complex — Synthesis is ready. After all, the tool is there for effectiveness — to get the job done easier, faster, better. Let’s talk about your project and custom tools need.

For Jigs & Fixtures.

When you need consistent setups and quick changes for specialty components, you might just need some specialty fixtures or setup jigs. The right simple fixtures or jigs can drastically improve quality and increase throughput. Innovation in solutions with collaboration is our game. Call Synthesis.

Visualizing With Past Projects:

Manufacturing Machine
Rock & Roll Machine
The Challenge:
Replace an existing machine, then scale it larger to meet the client’s new manufacturing needs. Also, address heating, cooling and stiffness issues of the previous machine.
The Solution:
Like it’s predecessor, the new machine drives the mold as the whole machine rocks. However, the new one is larger, drives itself, and solves the heating and cooling issues. It also solves stiffness and drive issues to achieve peak performance.
With a design from Synthesis for straightforward fabrication, the customer built the machine, and increased their output.

Special Tools
Fire Damper Testing
The Challenge:
Invent and build a latch mechanism for ventilation fire dampers that gives instant release to close the ducts when a fire is present, while also allowing inspectors to test and validate damper function.
The Solution:
A simple device which is serviceable from either side in the ducting, has easy installation and removal, and withstands fire. With it, we designed and built a special, custom tool for inspectors — to simplify and assist with periodic testing requirements of the fire damper code.

Process Machine
Lamination Machine
The Challenge:
In one application, commercial lamination machines were burning out in a few weeks. The alarming failure rate created staggering losses in product, production time and repair costs.
The Solution:
Borrowing from another industry (laser printers), Synthesis developed a custom machine to increase throughput with accurate control of heat, speed and pressure. The three custom machine design originally built lasted years (rather than weeks).
Increases in production uptime more than paid for the custom machines in just a few months.

Testing Machine
Durability and Intensity Testing
The Challenge:
Custom machine design and build for testing to replicate rare failures from the road. It must also perform routine product durability testing.
The Solution:
A table mounted machine with variabilities to facilitate both needs. Springs change, dampers change, and controls for speed and direction make the machine act and test in very different ways.
With the new machine, the issues were replicated, the design changed, then the new product was verified. Standard durability testing is ongoing (for several years) giving the customer continued confidence for product safety.

Machining Fixtures
Chainring CNC Fixture
The Challenge:
For small batches and prototypes, the customer needed a fixture for CNC machining to accommodate all different sizes of chainrings. The fixture and process had to be cost effective for short run production (speed), yet flexible enough to prototype new designs.
The Solution:
A 3 station CNC fixture with flexible machining options. One ring — whether prototype or production, is cut with each door open. With amazing flexibility, the fixture has produced thousands of chainrings in many sizes, just slightly slower than dedicated production machines.

Continuous, Harsh Duty
Shooting Range Reset
The Challenge:
Build a simple, portable machine to survive the harsh environment of an outdoor shooting range, to reset targets after being shot. Oh, and it must be portable at half the size and half the weight of the competition.
The Solution:
Taking solutions from several other industries, Synthesis developed a custom machine that takes a beating over and over, and continues to function. Challenges for electronics with impulse, shrapnel and other aspects of this extremely harsh environment were overcome through product development.

More examples: Case Study – Safety on the Ski Slopes

Then, browse the Portfolio, and our Case Studies Library.

Working With Synthesis

Every project is unique, as are the solutions. Synthesis is on the job, from concept to final build.

Listen, Identify and Understand Project Needs

Collaborate & Reason Together to Find the Right Solution

Customize and Design the Solution

Build, or Oversee the Project Construction, Then Integrate

Questions? Contact Us Now.

Results Matter

If Proof is in the Pudding . . . Then
Let’s Look at Benefits Our Custom Machine Clients Enjoy

Seamless Throughput

A new laminating machine that outlasted its predecessor by 50 times the life — totally avoiding costly production delays and maintenance nightmares.

Increased
Safety

Automating a dangerous process reduced workplace accidents, keeping workers safe and on the job. It also lowers insurance, medical, and time-off costs.

Time & Resource
Saving

On-site crushing and compacting custom machine design for one contractor eliminates multiple trips to the landfill and frees up valuable human resources.

Better Job Performance

A simple tool helps machinists accurately place a large, flexible product to perform the needed operations, to decrease scrap, and to increase quality.

If there’s a repetitive task you perform, then a machine, a fixture, a jig or a special tool can probably help you do it better, faster, and safer.

Let’s Talk About Ways To Accelerate

The Cost Of Waiting

Custom machines are always an investment, but they are part of the long game. Time and again, we help companies save money, increase throughput, improve efficiency, or avoid costly medical bills and even lawsuits.

As part of the initial process, we discuss the benefits custom machine design will bring to your company. In the analysis you’ll determine if gaining speed, precision, time and consistency is worth the investment.

Waiting delays the potential profits and reduced stress of greater efficiency.

Start The Conversation With An Inquiry

If you’re tired of making do or putting bandaids on a problem, it’s time for action. There is a better way, and now is the time to start the savings.

Let’s Find A Solution, then Build It Together

How Can We Help?

More Examples, More Ideas – Custom Machine Design

Below are a few more examples of projects we’ve worked on. Of course, your needs are different which is why we design custom. If you don’t see something here that’s similar to what you need, we are only a call away. Let us know how we can support you.