Experience and expertise helped in this situation.
Case Study 2
Experience and expertise are only as valuable as the
willingness to use them. At Starbase, there is no such
thing as a routine job; only new challenges that need
to be met head on.
During a review of a recent estimate request for the
development of a new part, Starbase experience came to
the table in a remarkably effective way. The client, an
international drug delivery company, was looking for estimates
for the production of a new needle protection device.
During a review of the design, engineers at Starbase identified
a number of issues relating to the client's complex part
design. The client decided to give Starbase a chance to
prototype the part from the ground up.
Designers at Starbase took on the challenge with an added
twist. The client wanted to use a production tool shop
for the prototypes so they could use the information learned
on the prototypes for the production tools. And they needed
parts in 6 weeks. Starbase accepted the challenge, and
working with the customer’s solid models plus the
design changes developed at Starbase to improve the part
and tool function, the deadline was met. The quality of
the parts was much better than they could have gotten
from a rapid prototype shop, and were, in fact so good
the client began to use the parts for consumer testing,
assembly equipment design, and reliability testing.
The rapid and effective turnaround of the design gave
the program a tremendous surge forward, and moved Starbase
into the next phase of the development: pre-production
tooling. To produce the increased volume of plastic parts
needed for the myriad of FDA evaluations and reviews that
were happening, and yet not invest fully in high cavitation
production tooling, pre-production tools that would produce
1⁄4 the volume of parts were built. The pre-production
tools were designed with tooling stacks that would be
interchangeable with the final production molds. These
molds proved to be tremendously valuable for reviewing
and understanding the tight tolerances and final tweaks
needed to fine tune the production molds, and save costly
rework on a high cavitation mold.
The final and most critical step was to build multiple
production molds to identical tolerances, and to manufacture
production parts that would pass strict quality control
standards. To help in this effort three of the client's
molding machines was installed in Starbase’s Tech
Center to exactly duplicate the final production environment.
This created the opportunity to calibrate the molds performance
and baseline the production run before final delivery
to the client's production team.
for a complex part under a tight deadline. The
Deep expertise and understanding of the
complete process at Starbase. The final
Making it to market with a cost effective
FDA approved part.