Machinery makes life simpler, easier and faster. We design Custom Machines to meet demanding business goals.
An Automated Machine, a Custom Tool, a Jig or Process Fixture. Save time and money while improving consistency and quality.
A Custom Machine can take the pressure off. If you're combating production overloads, trying to improve precision, or looking for a safer, faster process — a custom machine or tool may be the answer.
If there is a Repetitive Task you Perform,
Then the right Machine, or Special Tool can
probably help you do it Better, Faster, and Safer.
A look back can say a lot. Here are a few examples showing where we have been - Custom Machine, and special tools. Click the + icons to read about the solutions.
The Challenge:
Replace an existing machine, and scale it up to meet new manufacturing needs. Also, address cooling and stiffness issues of the previous unit.
The Solution:
Like it’s predecessor, the new machine turns a mold as the whole machine rocks end to end. However, the new one is larger, stiffer, drives itself, and solves the cooling, to achieve peak performance.
With the design from Synthesis, the customer built the machine. It now runs with increases in both product quality and total output.
The Challenge:
Design and build a custom machine for testing to replicate rare failures from actual customers. It must also perform routine product durability testing.
The Solution:
A table mounted machine (not the one in the photo) with various controls for Springs, Dampers, Speed and Direction to make the machine act and test in very different ways. It is amazingly violent!
The new machine replicated the issues, (then we improved the product design), and verified everything. Standard durability testing is still ongoing (for many years) giving the customer continued confidence for product safety.
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 (pictured) is serviceable from either side in the ducting, has easy installation and removal by using a special tool (not shown) that opens the damper for installation, inspection and testing. The tool is small enough and simple enough for the workmen to carry into the duct, but large enough and strong enough to assist with periodic testing requirements of the fire damper code.
The Challenge:
For small batches and prototypes, the customer needed a fixture for CNC machining to accommodate many sizes of chainrings. The fixture and process had to be cost effective for short run production (speed), yet flexible enough to also prototype new designs.
The Solution:
A 3 station CNC fixture with flexible machining options. 3 rings are in production at once so one is finished at each door open.
With amazing flexibility, the fixture has produced thousands of chainrings in many sizes, just slightly slower than dedicated production machines.
The Challenge:
For one customer, his commercial lamination machines were burning out in only a few weeks. The alarming failure rate created staggering losses in production time, repair costs and replacements.
The Solution:
Borrowing concepts from another industry, Synthesis developed a custom machine to increase throughput with accurate control of heat, speed and pressure. The 3 custom machines originally designed and built lasted years (rather than weeks). Then some repair, and they are still in service.
Increases in production uptime more than paid for the custom machine builds in just a few months. Now, it's all extra profit.
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. Yet, be repeatedly 06 energy (and under) capable.
The Solution:
Taking solutions from several other industries, Synthesis developed an instrument that takes a beating over and over, in the harsh conditions, and continues to function. Challenges for electronics with impulse, fine shrapnel and other aspects of this extremely harsh environment were overcome through innovation in product development. (Image shows the internals only.)
Additional custom machine examples (with more detail) are in Engineering Case Studies in the library. For instance, this Case Study – Safety on the Ski Slopes is a cool addition to an existing tractor.
Machines are all about making life simpler by making jobs easier. They help us do things that we could not otherwise accomplish, or even want to do. Some machines are simple, some complex. Jigs and Fixtures are not really machines, and yet they have many of the same benefits in saving time, improving quality, and making a job more pleasant.
Custom machines are a feature of Synthesis. It’s Product Development as a one-off special. Whether it is by simple hand operation, or full automation – or a fixture, or a jig or custom tool – we do it. We have made machines in micro size, and in XL. If this is something you need, we should talk. We design and build for specific applications – large or small, manual or automated.
Every customer has unique circumstances. That means together we must consider the application to maximize the benefit of investment. Custom is not cheap, but the end benefits with efficiency, improved throughput, and higher quality can mean higher profits and a significant ROI – when the application is right. Talk to us.
A Custom Machines is an investment for the long game. Time and again, we help companies improve profits, by increasing throughput or improving efficiency, or avoiding costly medical bills.
If you are reading this, then you already know where your benefits can come. Custom tools are not always right, so we'll help you think through it. Waiting also has a cost, however, so look ahead and plan for success.
Below are a few more examples of projects we have worked on. Large and small. (Far too many to show them all.) Of course, your needs are different, which is why we design each machine custom. Bring us your ideas, then together we can discuss what is feasible. Maybe we can work a little innovative magic to build a machine for you. We are only a call away.
