Custom Machines, Tools & Fixtures

Crusher Automated Custom Machine

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

Machines are all about making life simpler, easier and making some of our jobs faster.  The right machine for the job makes all the difference.  When it’s reliable and specifically tuned to the demands of your business, it certainly helps meet the business goals.

Saving time, money, and creating a safer environment are what machines do best.  Whether it’s a fully automated machine, a simple Jig, Tool or Fixture — Custom Machines & Special Tools help get things done faster, easier, and more consistently.

Inefficiencies are Stressful

If you’re combating frequent production breaks, struggling to improve precision, or looking create a safer, faster process, custom machines are often the answer.

Companies, Both Large & Small
Hire Synthesis to Build Machines

Building a custom machine is a big decision.  Hiring Synthesis to build a custom fixture, jig or tool will make sure you have a solution that is on-point to save you time and money in the long run.

From large automated manufacturing or testing machines on down to process fixtures and simple customized tools, Synthesis can find the path to a better process for your business.  Our experience in a variety of fields gives us access to a surprising number of ideas.

Visualizing With Past Projects:

Manufacturing Custom Machine
  • Rock & Roll Machine

    The Challenge:
    Replace an existing machine, scaled larger to meet the client’s manufacturing needs while addressing 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.

Custom  and Special Tools
  • Fire Damper Testing

    The Challenge:
    Build a latch mechanism to use with ventilation fire dampers that gives instant release to close the ducts when a fire is present, and also allow inspectors to validate function.

    The Solution:
    A simple device, serviceable from either side in the ducting, easy installation and removal, and withstands fire.  With it, we designed a special tool for inspectors to assist with periodic testing according to ventilation fire damper code requirements.

Design & Custom Machine Design
  • Lamination Machine

    The Challenge:
    In one application, the commercial lamination machines were burning out in a matter of a few weeks.  The alarming failure rate created staggering losses in product, production time and repair requirements.

    The Solution:
    Borrowing from another industry (laser printers), Synthesis developed a custom machine that increased throughput by accurate control of heat, speed and pressure.  The three custom machines originally built lasted years (rather than weeks).

    The increased production and uptime more than paid for the custom machines in just a few months.

Specialized Automated Testing Machine
  • Durability and Intensity Testing

    The Challenge:
    Design and build a custom machine that can replicate rare failures that occur on the road.  The machine must also perform routine durability testing.

    The Solution:
    A table mounted machine with variabilities to facilitate both needs.  Springs can change, dampers can 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, and the new design verified. Standard durability testing is on-going giving the customer continued confidence in the safety of their product.

Fixtures and Tools
  • Chainring CNC Fixture

    The Challenge:
    For small batches, the customer needed a fixture for CNC machining on all different sizes of chainrings.  And, cost effective for short run production (speed), yet flexible enough for prototyping new designs.

    The Solution:
    A 3 station CNC fixture with special, flexible machining stations.  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 Duty Workhorse Machines
  • 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 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 still resets.  Challenges for electronics with impulse, shrapnel and other aspects of this extremely harsh environment were overcome through product development.

For more examples, please browse the Portfolio, and our Case Studies Library.

Working With Synthesis

Every project is unique.  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 Build, Then Integrate

Questions?  Ask Here.

Results Matter

If the Proof of the Pudding is in the Eating . . . 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.

Custom Machines Direction

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.

Custom Machines Direction

Time & Resource
Saving

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

Custom Machines Direction

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.

Custom Machines Direction

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

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 or improve efficiency or avoid costly medical bills and even lawsuits.

As part of the initial process, we discuss the benefits a custom machine 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 d0 or putting bandaids on a problem, it’s time for action.  You know there is a better way.  Now is the time to start the savings and improve your process.

Let’s Find A Solution and Build It Together

More Examples, More Ideas

These are just a few examples of projects we’ve worked on.  If you don’t see something here that’s similar to what you need, we are only a call away.  Let us show you how we can improve the situation.

Machines And Automation

  • Manufacturing Assembly Machines

    Manufacturing Assembly Machines

  • Production Acceleration

    Production Acceleration

  • Testing Durability Machines

    Testing Durability Machines

  • Robotic & Automatic

    Robotic & Automatic

  • Just For Fun Machines

    Just For Fun Machines

  • Serious Safety For Machines

    Serious Safety For Machines

  • Small, Simple Machines

    Small, Simple Machines

  • Complex Process Functions

    Complex Process Functions

  • Robotic Machines

    Robotic Machines

  • Innovative Process Optimization

    Innovative Process Optimization

  • Adjustable Setup Machines

    Adjustable Setup Machines

  • Unique Function

    Unique Function

  • How To Categorize It?

    How To Categorize It?

  • Automated Packaging

    Automated Packaging

  • Built, Delivered & Installed

    Built, Delivered & Installed

Manufacturing Support And Consulting

  • Tooling Design

    Tooling Design

  • Detailed Assembly Fixturing

    Detailed Assembly Fixturing

  • Process Fixturing

    Process Fixturing

  • Design For Manufacturing

    Design For Manufacturing

  • Manufacturing Machines

    Manufacturing Machines

  • Insert Mold Design

    Insert Mold Design

  • Special Tools Minimize Cycles

    Special Tools Minimize Cycles

  • Process Methodology

    Process Methodology

  • Design For Assembly

    Design For Assembly

  • Robotic Manufacturing Machines

    Robotic Manufacturing Machines

  • CNC And Other Fixtures

    CNC And Other Fixtures

  • Specialty Assembly Machines

    Specialty Assembly Machines

  • Mold Design Concepts

    Mold Design Concepts